Method and apparatus for fabricating contoured laminate structures
First Claim
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1. An apparatus for fabricating each of a plurality of differing laminate structures in a family of structures having common features, comprising:
- a plurality of separate fabrication modules each locally adapted to fabricate a section of the laminate structure on a corresponding tool, the fabrication modules being reconfigurable to fabricate each of the laminate structures in the family thereof, wherein each of the fabrication modules includes a track in which a portion of a forming member is local mounted;
the forming member adapted for forming laminate plies over the tool, the forming member extending along a length of the fabrication modules, portions of the forming member being mounted on each of the fabrication 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
a controller for controlling and coordinating automated operation of the fabrication modules.
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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.
41 Citations
43 Claims
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1. An apparatus for fabricating each of a plurality of differing laminate structures in a family of structures having common features, comprising:
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a plurality of separate fabrication modules each locally adapted to fabricate a section of the laminate structure on a corresponding tool, the fabrication modules being reconfigurable to fabricate each of the laminate structures in the family thereof, wherein each of the fabrication modules includes a track in which a portion of a forming member is local mounted; the forming member adapted for forming laminate plies over the tool, the forming member extending along a length of the fabrication modules, portions of the forming member being mounted on each of the fabrication 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 a controller for controlling and coordinating automated operation of the fabrication modules. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of fabricating each of a plurality of differing parts in a family of parts having common features, wherein each of the parts is fabricated using a unique tool, comprising:
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arranging a plurality of separate, substantially identical fabrication modules to substantially match a tool on which one of the parts is to be fabricated, wherein each of the fabrication modules includes a track; locally mounting portions of a forming member within the track along substantially the entire length of the fabrication modules, the portions of the forming member being mounted on each of the fabrication 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; adapting each of the fabrication modules to a local section of the tool; and
,controlling and coordinating operation of the fabrication modules to fabricate portions of the part over a corresponding section of the tool. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21)
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22. An apparatus for fabricating each of a plurality of differing laminate structures in a family of structures having common features, comprising:
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a flexible ply carrier adapted to hold at least one laminate ply thereon; a plurality of separate fabrication modules each locally adapted to fabricate a section of the laminate structure on a corresponding tool, wherein each of the fabrication modules includes a pair of spaced apart tracks adapted to releasably hold the ply carrier, the fabrication modules being reconfigurable to fabricate each of the laminate structures in the family thereof; a forming member adapted for forming laminate plies over the tool, the forming member extending along a length of the fabrication modules, portions of the forming member being mounted on each of the fabrication modules for movement over the tool along at least two axes; a ply carrier control assembly for holding the ply carrier in tension as the forming member forms the ply over the tool; and a controller for controlling and coordinating automated operation of the fabrication modules. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A method of fabricating each of a plurality of differing parts in a family of parts having common features, wherein each of the parts is fabricated using a unique tool, comprising:
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arranging a plurality of separate, substantially identical fabrication modules to substantially match a tool on which one of the parts is to be fabricated, wherein each of the fabrication modules includes a pair of spaced apart tracks, the tracks having a ply carrier held thereon; locally mounting portions of a forming member within the track along substantially the entire length of the fabrication modules, the portions of the forming member being mounted on each of the fabrication modules for movement over the tool along at least two axes; adapting each of the fabrication modules to a local section of the tool; and
,holding the ply carrier in tension on the tracks while the forming member forms a ply over the tool; controlling and coordinating operation of the fabrication modules to fabricate portions of the part over a corresponding section of the tool. - View Dependent Claims (36, 37, 38, 39, 40, 41, 42, 43)
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Specification