Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections

• US 20060108058A1
• Filed: 11/24/2004
• Published: 05/25/2006
• Est. Priority Date: 11/24/2004
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Piehl, Marc J., Anderson, Donald A., Sweetin, Joseph L., Chapman, Michael R., Grose, Douglas L., Watson, Robert M.
• Granted Patent: US 7,503,368 B2
• Time in Patent Office: Days
• US Class Current: 156/245
• CPC Class Codes: B29C 70/323 on the inner surface of a rotating mould
• CPC Class Codes: B29C 70/386 Automated tape laying [ATL]
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29L 2031/3082 Fuselages
• CPC Class Codes: B64C 1/068 Fuselage sections
• CPC Class Codes: B64C 1/12 Construction or attachment of skin panels
• CPC Class Codes: B64F 5/10 Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/1348 Work traversing type
• CPC Class Codes: Y10T 156/1702 For plural parts or plural areas of single part
• CPC Class Codes: Y10T 156/1754 At least two applied side by side to common base
• CPC Class Codes: Y10T 156/1788 Work traversing type and/or means applying work to wall or static structure
• CPC Class Codes: Y10T 156/1795 Implement carried web supply

Abstract

Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Claims

1. A system for manufacturing a composite shell structure, the system comprising:

a tool having a mold surface;

an equipment support member configured to extend adjacent to the mold surface; and

a composite material applicator carried by the equipment support member and configured to apply composite material to the interior mold surface.

2. The system of claim 1 wherein the tool is a lay-up mandrel, and wherein the equipment support member extends at least partially through the lay-up mandrel.

3. The system of claim 1 wherein the tool is a female tool having an interior mold surface.

4. The system of claim 1 wherein the mold surface of the tool extends for 360 degrees about an axis.

5. The system of claim 1 wherein the composite material applicator is movable relative to the equipment support member to apply composite material to the mold surface.

6. The system of claim 1 wherein the composite material applicator carries unidirectional composite material for application onto the mold surface.

7. The system of claim 1 wherein the composite material applicator carries bidirectional composite cloth for application onto the mold surface.

8. The system of claim 1 wherein the equipment support member extends along a longitudinal axis, and wherein the composite material applicator is configured to apply composite material for 360 degrees around the longitudinal axis.

9. The system of claim 1 wherein the equipment support member extends along a longitudinal axis, and wherein the composite material applicator is configured to apply composite material parallel to the longitudinal axis.

10. The system of claim 1 wherein the composite material applicator is a first composite material applicator configured to apply a first composite material to the mold surface of the tool, and wherein the system further comprises a second composite material applicator carried by the equipment support member, wherein the second composite material applicator is configured to apply a second composite material to the first composite material on the mold surface of the tool.

11. The system of claim 1 wherein the composite material applicator is a first composite material applicator configured to apply bidirectional composite cloth to the mold surface of the tool, and wherein the system further comprises a second composite material applicator carried by the equipment support member, wherein the second composite material applicator is configured to apply unidirectional composite material to the bidirectional composite cloth on the mold surface of the tool.

12. The system of claim 1 wherein the composite material applicator is a first composite material applicator configured to apply bidirectional composite cloth to the mold surface of the tool, and wherein the system further comprises:

a second composite material applicator carried by the equipment support member, wherein the second composite material applicator is configured to apply unidirectional composite material to the mold surface of the tool; and

a third composite material applicator carried by the equipment support member, wherein the third composite material applicator is configured to apply preformed composite doublers to the unidirectional composite material on the mold surface of the tool.

13. The system of claim 1 wherein the tool is an aircraft fuselage section tool.

14. The system of claim 1, further comprising a stanchion configured to be positioned toward an open end of the tool, wherein the equipment support member extends outwardly from the stanchion.

15. The system of claim 1, further comprising a stanchion configured to be positioned toward an open end of the tool, wherein the stanchion includes a drive assembly configured to rotate the equipment support member about a longitudinal axis.

16. The system of claim 1, further comprising:

a first stanchion configured to be positioned toward a first open end of the tool, wherein the equipment support member extends outwardly from the first stanchion; and

a second stanchion configured to be positioned toward a second open end of the tool, wherein the equipment support member is configured to extend through the tool and releasably engage the second stanchion.

17. The system of claim 1, further comprising a stanchion configured to be positioned toward an open end of the tool, wherein the equipment support member extends outwardly from the stanchion, and wherein the stanchion is movable relative to the tool to insert the equipment support member through at least a portion of the tool.

18. The system of claim 1, further comprising:

a first stanchion configured to be positioned toward a first open end of the tool, wherein the equipment support member extends outwardly from the first stanchion; and

a second stanchion configured to be positioned toward a second open end of the tool, wherein the first stanchion is movable relative to the second stanchion to insert the equipment support member through the tool and releasably engage the equipment support member with the second stanchion.

19. A system for manufacturing a composite shell structure with a tool having a mold surface, the system comprising:

a first equipment support member configured to be positioned at least partially within the female tool;

a second equipment support member configured to be positioned at least partially outside of the female tool in operational alignment with the first equipment support member; and

a stiffener placement tool having a plurality of stiffener holding portions configured to carry a plurality of corresponding stiffeners, wherein the stiffener placement tool is movable from the second equipment support member to the first equipment support member to place the plurality of stiffeners at least proximate the interior mold surface of the female tool.

20. The system of claim 19 wherein the first equipment support member includes an elongate boom extending outwardly from a movable stanchion.

21. The system of claim 19, further comprising:

a first rail attached to the first equipment support member, wherein the first rail is configured to carry the stiffener placement tool when the stiffener placement tool is moved from the second equipment support member to the first equipment support member; and

a second rail attached to the second equipment support member, wherein the second rail is configured to carry the stiffener placement tool when the stiffener placement tool is moved from the first equipment support member to the second equipment support member.

22. The system of claim 19, further comprising:

a first stanchion, wherein the first equipment support member extends outwardly from the first stanchion; and

a second stanchion, wherein the second equipment support member extends outwardly from the second stanchion, and wherein the first stanchion is movable relative to the second stanchion to releasably engage a first distal end of the first equipment support member with a second distal end of the second equipment support member.

23. The system of claim 19 wherein the interior mold surface of the female tool extends between first and second open ends of the female tool, and wherein the stiffener holding portions of the stiffener placement tool are configured to carry a plurality of stiffeners having lengths that are at least approximately equivalent to the length of the interior mold surface.

24. The system of claim 19 wherein the stiffener placement tool includes at least one actuator configured to press a portion of the plurality of stiffeners against a lay-up on the interior mold surface of the female tool.

25. The system of claim 19 wherein the stiffener placement tool includes at least one actuator configured to extend in a radial direction to press a portion of the plurality of stiffeners against a lay-up on the interior mold surface of the female tool.

26. The system of claim 19 wherein the stiffener holding portions of the stiffener placement tool are configured to carry a plurality of hat-section stiffeners.

27. A system for manufacturing a composite shell structure on a female tool having an interior mold surface, the system comprising:

a first equipment support member configured to be positioned at least partially within the female tool;

a second equipment support member configured to be positioned at least partially outside of the female tool in operational alignment with the first equipment support member; and

a vacuum bag dispenser configured to carry vacuum bag material, wherein the vacuum bag dispenser is movable from the second equipment support member to the first equipment support member to dispense the vacuum bag material over at least a portion of a composite lay-up on the interior mold surface of the female tool.

28. The system of claim 27 wherein the first equipment support member includes an elongate boom extending outwardly from a movable stanchion.

29. The system of claim 27, further comprising:

a first rail attached to the first equipment support member, wherein the first rail is configured to carry the vacuum bag dispenser when the vacuum bag dispenser is moved from the second equipment support member to the first equipment support member; and

a second rail attached to the second equipment support member, wherein the second rail is configured to carry the vacuum bag dispenser when the vacuum bag dispenser is moved from the first equipment support member to the second equipment support member.

30. The system of claim 27, further comprising:

a first stanchion, wherein the first equipment support member extends outwardly from the first stanchion; and

a second stanchion, wherein the second equipment support member extends outwardly from the second stanchion, and wherein the first stanchion is movable relative to the second stanchion to releasably engage a first distal end of the first equipment support member with a second distal end of the second equipment support member.

31. A system for manufacturing a composite shell structure, the system comprising:

a female tool having an interior mold surface;

a first equipment support member configured to be positioned at least partially within the female tool;

a composite material applicator carried by the first equipment support member and configured to apply composite material to the interior mold surface;

a second equipment support member configured to be positioned at least partially within the female tool; and

a stiffener placement tool carried by the second equipment support member and configured to place a plurality of stiffeners at least proximate the interior mold surface of the female tool.

32. The system of claim 31 wherein the female tool is a lay-up mandrel, and wherein the first and second equipment support members are configured to extend at least partially through the lay-up mandrel.

33. The system of claim 31 wherein the interior mold surface of the female tool extends for 360 degrees about an axis.

a second equipment support member configured to be positioned at least partially outside of the female tool in operational alignment with the first equipment support member;

and

34. The system of claim 31, further comprising a vacuum bag dispenser configured to carry vacuum bag material, wherein the vacuum bag dispenser is movable to the second equipment support member to dispense the vacuum bag material over at least a portion of a composite lay-up on the interior mold surface of the female tool.

35. A stiffener positioning tool for positioning stiffeners relative to a mold surface, the tool comprising:

at least one stiffener positioner, the stiffener positioner having a plurality of stiffener holding portions configured to carry a plurality of corresponding stiffeners; and

at least one actuator operably coupled to the stiffener positioner, wherein the actuator is configured to move the stiffener positioner and press the plurality of stiffeners against the mold surface.

36. The stiffener positioning tool of claim 35 wherein the plurality of stiffener holding portions includes a plurality of elongate channels arranged in parallel to each other.

37. The stiffener positioning tool of claim 35 wherein the plurality of stiffener holding portions are configured to carry the plurality of corresponding stiffeners in a non-planar arrangement.

38. The stiffener positioning tool of claim 35 wherein the at least one actuator is configured to move the stiffener positioner and press the plurality of stiffeners against a curved mold surface.

39. The stiffener positioning tool of claim 35 wherein the mold surface extends for 360 degrees around an axis, and wherein the at least one actuator is configured to press the plurality of stiffeners outwardly against the mold surface.

40. The stiffener positioning tool of claim 35 wherein the plurality of stiffener holding portions are configured to carry a plurality of composite hat-section stiffeners.

41. The stiffener positioning tool of claim 35 wherein the at least one stiffener positioner is a first stiffener positioner having a first plurality of stiffener holding portions configured to carry a first plurality of corresponding stiffeners, wherein the at least one actuator is a first actuator, and wherein the tool further comprises:

a second stiffener positioner positioned adjacent to the first stiffener positioner, the second stiffener positioner having a second plurality of stiffener holding portions configured to carry a second plurality of corresponding stiffeners; and

a second actuator operably coupled to the second stiffener positioner, wherein the second actuator is configured to move the second stiffener positioner and press the second plurality of corresponding stiffeners against the mold surface.

42. An apparatus for temporarily attaching a first element to a second element, the apparatus comprising:

a first chamber having a first plurality of holes in a first sidewall, wherein evacuation of the first chamber when the first plurality of holes face the first element causes the first chamber to be pressed against the first element; and

a second chamber separate from the first chamber, the second chamber having a second plurality of holes in a second sidewall, wherein evacuation of the second chamber when the second plurality of holes face the second element causes the second chamber to be pressed against the second element.

43. The apparatus of claim 42 wherein the first chamber is separated from the second chamber by a common wall.

44. The apparatus of claim 42 wherein the first plurality of holes in the first chamber face a first direction, and wherein the second plurality of holes in the second chamber face a second direction, opposite to the first direction.

45. The apparatus of claim 42 wherein the first chamber is a first portion of an enclosed body and the second chamber is a second portion of the enclosed body.

46. The apparatus of claim 42 wherein the first chamber is a first portion of a cylindrical cross-section, and the second chamber is a second portion of the cylindrical cross-section.

47. The apparatus of claim 42 wherein the first plurality of holes are configured to be positioned against a mold surface of a tool, and the second plurality of holes is configured to be positioned against a vacuum bag.

48. A method for manufacturing a shell structure, the method comprising:

applying composite material to an interior mold surface of a tool to form a skin lay-up extending 360 degrees around an axis;

positioning a plurality of stiffeners on an inner surface of the skin lay-up; and

at least partially cocuring the skin lay-up and the plurality of stiffeners to bond the plurality of stiffeners to the skin lay-up.

49. The method of claim 48, further comprising:

positioning vacuum bag material adjacent to the plurality of stiffeners and the skin lay-up; and

evacuating a volume between the vacuum bag material and the skin lay-up to press the plurality of stiffeners and the skin lay-up outwardly against the interior mold surface of the tool.

50. The method of claim 48 wherein positioning a plurality of stiffeners on an inner surface of the skin lay-up includes positioning a plurality of at least approximately straight stiffeners on the inner surface of the skin lay-up.

51. The method of claim 48 wherein applying composite material to an interior mold surface includes automatically applying composite material to an interior surface of a lay-up mandrel with a composite material applicator.

52. The method of claim 48 wherein applying composite material to an interior mold surface includes automatically applying composite material to an interior surface of a lay-up mandrel with a composite material applicator configured to rotate 360 degrees around the inside of the lay-up mandrel.

53. The method of claim 48 wherein applying composite material to an interior mold surface includes automatically applying bidirectional composite cloth to an interior surface of a lay-up mandrel with a composite material applicator.

54. The method of claim 48 wherein applying composite material to an interior mold surface includes automatically applying unidirectional composite material to an interior surface of a lay-up mandrel with a composite material applicator.

55. A method for applying composite material to an interior mold surface of a lay-up mandrel, the method comprising:

extending an equipment support member through at least a portion of the lay-up mandrel;

moving a composite material applicator on the equipment support member from a first position proximate to a first end of the lay-up mandrel to a second position inside the lay-up mandrel;

applying composite material from the composite material applicator to the interior mold surface when the composite material applicator is inside the lay-up mandrel; and

moving the composite material applicator from the second position inside the lay-up mandrel to a third position proximate to a second end of the lay-up mandrel.

56. The method of claim 55 wherein extending an equipment support member through the lay-up mandrel includes extending a boom through the lay-up mandrel.

57. The method of claim 55 wherein extending an equipment support member through the lay-up mandrel includes moving a first stanchion to insert a boom through the lay-up mandrel and engage a distal end of the boom with a second stanchion.

58. The method of claim 55 wherein moving a composite material applicator from a first position includes moving the composite material applicator from a first position outside the lay-up mandrel, and wherein moving the composite material applicator to a third position includes moving the composite material applicator to a third position outside the lay-up mandrel.

59. The method of claim 55 wherein the composite material applicator is a first composite material applicator, and wherein the method further comprises:

moving a second composite material applicator on the equipment support member from a fourth position proximate to the first end of the lay-up mandrel to a fifth position inside the lay-up mandrel;

applying composite material from the second composite material applicator to the interior mold surface when the second composite material applicator is inside the lay-up mandrel; and

moving the second composite material applicator from the fifth position inside the lay-up mandrel to a sixth position proximate to the second end of the lay-up mandrel.

60. The method of claim 55 wherein the composite material applicator is a first composite material applicator configured to apply bidirectional composite material to the interior mold surface, and wherein the method further comprises:

moving a second composite material applicator on the equipment support member from a fourth position proximate to the first end of the lay-up mandrel to a fifth position inside the lay-up mandrel;

applying unidirectional composite material from the second composite material applicator to the interior mold surface when the second composite material applicator is inside the lay-up mandrel; and

moving the second composite material applicator from the fifth position inside the lay-up mandrel to a sixth position proximate to the second end of the lay-up mandrel.

61. A method for manufacturing a shell structure, the method comprising:

extending an equipment support member through at least a portion of a lay-up mandrel;

moving a composite material applicator on the equipment support member from a first position proximate to a first end of the lay-up mandrel to a second position inside the lay-up mandrel;

applying composite material from the composite material applicator to an interior mold surface of the lay-up mandrel;

moving the composite material applicator from the second position inside the lay-up mandrel to a third position proximate to a second end of the lay-up mandrel;

positioning a plurality of stiffeners on the composite material inside the lay-up mandrel; and

at least partially cocuring the stiffeners and the composite material.

62. The method of claim 61, further comprising:

positioning vacuum bag material adjacent to the plurality of stiffeners and the composite material; and

evacuating a volume between the vacuum bag material and the composite material to press the stiffeners and the composite material outwardly against the interior mold surface of the lay-up mandrel.

63. The method of claim 61 wherein positioning a plurality of stiffeners includes positioning a plurality of at least approximately straight stiffeners on an inner surface of the composite material.

64. The method of claim 61 wherein extending an equipment support member through at least a portion of the lay-up mandrel includes extending a boom through the lay-up mandrel.

65. The method of claim 61, further comprising:

separating the lay-up mandrel into at least two pieces; and

removing the cocured stiffeners and composite material from the mandrel.

66. A method for temporarily attaching a first element to a second element, the method comprising:

positioning a first plurality of holes in a first chamber of a temporary vacuum apparatus against the first element;

evacuating the first chamber to temporarily attach the temporary vacuum apparatus to the first element;

positioning the second element against a second plurality of holes in a second chamber of the temporary vacuum apparatus; and

evacuating the second chamber to temporarily attach the second element to the temporary vacuum apparatus.

67. The method of claim 66 wherein evacuating the first chamber includes evacuating a first chamber in a first portion of an elongate member, and wherein evacuating the second chamber includes evacuating a second chamber in a second portion of the elongate member.

68. The method of claim 66 wherein positioning the second element against a second plurality of holes includes positioning a flexible sealing layer against the second plurality of holes.

69. A method for positioning vacuum bag material against a composite lay-up inside a female tool having an interior mold surface extending 360 degrees around an axis, the method comprising:

positioning a first portion of vacuum bag material against a first portion of the composite lay-up;

evacuating a first volume between the first portion of vacuum bag material and the first portion of the composite lay-up to hold the first portion of vacuum bag material against the first portion of the composite lay-up;

positioning a second portion of vacuum bag material against a second portion of the composite lay-up;

sealing a first edge region of the first portion of vacuum bag material to a second edge region of the second portion of vacuum bag material; and

evacuating a second volume between the second portion of vacuum bag material and the second portion of the composite lay-up to hold the second portion of vacuum bag material against the second portion of the composite lay-up.

70. The method of claim 69, further comprising:

positioning a third portion of vacuum bag material against a third portion of the composite lay-up;

sealing a third edge region of the third portion of vacuum bag material to at least one of a fourth edge region of the second portion of vacuum bag material and a fifth edge region of a fourth portion of vacuum bag material;

sealing a sixth edge region of the third portion of vacuum bag material to a seventh edge region of the first portion of vacuum bag material; and

evacuating a third volume between the third portion of vacuum bag material and the third portion of the composite lay-up to hold the third portion of vacuum bag material against the third portion of the composite lay-up.

71. A system for manufacturing a shell structure, the system comprising:

means for applying composite material to an interior mold surface of a tool to form a skin lay-up extending 360 degrees around an axis;

means for positioning a plurality of stiffeners on an inner surface of the skin lay-up; and

means for at least partially cocuring the skin lay-up and the plurality of stiffeners to bond the plurality of stiffeners to the skin lay-up.

72. The system of claim 71, further comprising:

means for positioning vacuum bag material over the plurality of stiffeners and the skin lay-up; and

means for evacuating a volume under the vacuum bag material to press the plurality of stiffeners and the skin lay-up outwardly against the interior mold surface of the tool.

73. The system of claim 71 wherein the means for positioning a plurality of stiffeners on an inner surface of the skin lay-up include means for positioning a plurality of at least approximately straight stiffeners on the inner surface of the skin lay-up.

74. The system of claim 71 wherein the means for applying composite material to an interior mold surface of a tool include means for applying composite material in a circumferential direction around the inside of a lay-up mandrel.

75. The system of claim 71 wherein the means for applying composite material to an interior mold surface of a tool include means for applying composite material in a longitudinal direction on the inside of a lay-up mandrel.

76. A system for applying composite material to an interior mold surface of a lay-up mandrel, the system comprising:

means for moving a composite material applicator from a first position outside the lay-up mandrel and proximate to a first end of the lay-up mandrel to a second position inside the lay-up mandrel;

means for applying composite material from the composite material applicator to the interior mold surface when the composite material applicator is inside the lay-up mandrel; and

means for moving the composite material applicator from the second position inside the lay-up mandrel to a third position outside the lay-up mandrel and proximate to a second end of the lay-up mandrel after the composite material has been applied to the interior mold surface.

77. The system of claim 76 wherein the composite material applicator is a first composite material applicator, and wherein the system further comprises:

means for moving a second composite material applicator from a fourth position proximate to the first end of the lay-up mandrel to a fifth position inside the lay-up mandrel;

means for moving a second composite material applicator from a fourth position proximate to the first end of the lay-up mandrel to a fifth position inside the lay-up mandrel;

means for applying composite material from the second composite material applicator to the interior mold surface when the second composite material applicator is inside the lay-up mandrel; and

means for moving the second composite material applicator from the fifth position inside the lay-up mandrel to a sixth position proximate to the second end of the lay-up mandrel.

78. The system of claim 76 wherein the composite material applicator is a first composite material applicator configured to apply bidirectional composite material to the interior mold surface, and wherein the system further comprises:

means for moving a second composite material applicator from a fourth position proximate to the first end of the lay-up mandrel to a fifth position inside the lay-up mandrel;

means for applying unidirectional composite material from the second composite material applicator to the interior mold surface when the second composite material applicator is inside the lay-up mandrel; and

means for moving the second composite material applicator from the fifth position inside the lay-up mandrel to a sixth position proximate to the second end of the lay-up mandrel.

79. A method for applying composite material to an interior mold surface of a lay-up mandrel, the method comprising:

positioning a first composite material applicator inside the lay-up mandrel;

positioning a second composite material applicator inside the lay-up mandrel;

and

simultaneously applying composite material from the first and second composite material applicators to the interior mold surface.

80. The method of claim 79 wherein positioning a first composite material applicator includes positioning a first tape head inside the lay-up mandrel, wherein positioning a second composite material applicator includes positioning a second tape head inside the lay-up mandrel, and wherein simultaneously applying composite material includes simultaneously applying tape from the first and second tape heads to the interior mold surface.