Composite ply placement system and method

Patent metadata

Field	Value
Publication number	US-11654641-B2
Application number	US-202117516050-A
Country	US
Kind code	B2
Filing date	Nov 1, 2021
Priority date	Dec 7, 2020
Publication date	May 23, 2023
Grant date	May 23, 2023

Abstract

A system for placing a composite ply includes a transfer end effector that is movable relative to a carrier transfer device, configured to convey a ply carrier that supports the composite ply, and a placement end effector that is movable relative to the transfer end effector and to a forming tool. The transfer end effector is configured to remove the ply carrier, supporting the composite ply, from the carrier transfer device and to position the ply carrier for removal by the placement end effector. The placement end effector is configured to remove the ply carrier from the transfer end effector and to apply the composite ply to the forming tool.

First claim

What is claimed is:

1. A system for placing a composite ply, the system comprising:
a transfer end effector that is movable relative to a carrier transfer device, configured to convey a ply carrier that supports the composite ply; and
a placement end effector that is movable relative to the transfer end effector and to a forming tool,
wherein:
the transfer end effector comprises a magnetic chuck that is configured to magnetically engage the ply carrier, supporting the composite ply, to remove the ply carrier from the carrier transfer device and to position the ply carrier for removal by the placement end effector; and
the placement end effector is configured to remove the ply carrier from the transfer end effector and to apply the composite ply to the forming tool.

2. The system of claim 1 , further comprising the ply carrier, wherein the ply carrier comprises:
a base plate, wherein the base plate is magnetic; and
a film positioned on the base plate and forming a ply support surface for the composite ply.

3. The system of claim 2 , wherein:
the magnetic chuck is configured to magnetically engage the base plate for removal of the ply carrier from the carrier transfer device by the transfer end effector; and
the magnetic chuck is further configured to magnetically disengage the base plate for removal of the ply carrier from the transfer end effector by the placement end effector.

4. The system of claim 2 , wherein:
the placement end effector comprises a vacuum chuck; and
the vacuum chuck is configured to selectively apply a retention vacuum to the base plate for removal of the ply carrier from the transfer end effector by the placement end effector.

5. The system of claim 1 , wherein:
the transfer end effector comprises:
a transfer frame; and
the magnetic chuck is coupled to the transfer frame and comprises a magnetic-chuck contact surface; and

the magnetic chuck is movable relative to the transfer frame to position the magnetic-chuck contact surface in contact with the composite ply, supported by the ply carrier, for removal of the ply carrier from the carrier transfer device by the transfer end effector.

6. The system of claim 5 , wherein the magnetic chuck further comprises:
a magnetic-chuck support member coupled to and movable relative to the transfer frame; and
a plurality of magnets coupled to the magnetic-chuck support member.

7. The system of claim 6 , wherein the magnetic chuck further comprises a magnetic-chuck pliable member coupled to the magnetic-chuck support member, opposite the transfer frame.

8. The system of claim 7 , wherein the plurality of magnets is movable relative to the magnetic-chuck support member.

9. The system of claim 8 , wherein:
the magnetic-chuck pliable member comprises a plurality of magnet openings; and
each one of the plurality of magnets is located within a corresponding one of the plurality of magnet openings of the magnetic-chuck pliable member.

10. The system of claim 8 , wherein the magnetic chuck further comprises:
a plurality of magnetic-chuck actuator rods extending through the magnetic-chuck support member and coupled to the plurality of magnets; and
a magnetic-chuck actuator configured to selectively extend or retract the plurality of magnetic-chuck actuator rods relative to the magnetic-chuck support member to move the plurality of magnets.

11. The system of claim 5 , wherein the transfer end effector further comprises a plurality of clamps configured to fix the ply carrier against the magnetic-chuck contact surface of the magnetic chuck.

12. The system of claim 5 , further comprising a transfer support platform coupled to the transfer frame of the transfer end effector,
wherein the transfer end effector is rotatable about a rotation axis relative to the transfer support platform to position the ply carrier for removal from the transfer end effector by the placement end effector.

13. The system of claim 5 , wherein:
the transfer end effector further comprises:
a transfer actuator coupled to the transfer frame and to the magnetic chuck; and
a transfer guide coupled to the transfer frame and to the magnetic chuck;

the transfer actuator is configured to control movement of the magnetic chuck relative to the transfer frame along a first movement axis;
the transfer guide is configured to direct movement of the magnetic chuck along the first movement axis; and
the transfer guide is further configured to enable movement of the magnetic chuck relative to the transfer frame along a float axis that is perpendicular to the first movement axis.

14. The system of claim 13 , wherein the transfer end effector comprises a first portion of a first indexing device that is configured to cooperate with a second portion of the first indexing device located on the carrier transfer device to index the magnetic chuck relative to the carrier transfer device.

15. The system of claim 1 , wherein:
the placement end effector comprises:
a placement frame; and
a vacuum chuck coupled to the placement frame and comprising a vacuum-chuck contact surface; and

the vacuum chuck is movable relative to the placement frame to position the vacuum-chuck contact surface in contact with the ply carrier, supporting the composite ply, for removal of the ply carrier from the transfer end effector by the placement end effector and to position the ply carrier for application of the composite ply to the forming tool by the placement end effector.

16. The system of claim 15 , wherein the vacuum chuck is pivotable about a pivot axis relative to the placement frame to orient the ply carrier for application of the composite ply to the forming tool by the placement end effector.

17. The system of claim 15 , further comprising a placement support platform coupled to the placement frame of the placement end effector, wherein the placement end effector is movable relative to the placement support platform to position the ply carrier for application of the composite ply to the forming tool by the placement end effector.

18. The system of claim 15 , wherein:
the placement end effector further comprises a placement actuator coupled to the placement frame and to the vacuum chuck; and
the placement actuator is configured to control movement of the vacuum chuck relative to the placement frame.

19. The system of claim 15 , wherein:
the transfer end effector comprises a first portion of a second indexing device;
the placement end effector comprises a second portion of the second indexing device; and
the first portion and the second portion of the second indexing device are configured to cooperate to index the placement end effector relative to the transfer end effector.

20. A manufacturing system for fabricating a composite structure, the system comprising:
a ply carrier comprising a ply support surface configured to support at least one composite ply, wherein the ply carrier is magnetic;
a carrier transfer device configured to convey the ply carrier;
a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier;
a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool, wherein the transfer system comprises:
the transfer end effector and the placement end effector of claim 1 ; and

a forming system configured to form the at least one composite ply over the at lea

Assignees

• Boeing Co

Inventors

• Ly Long
• Krajca Scott
• Jones Darrell
• Wilcoxson Chace
• Bunker Mark
• Crain Joel
• Chamberlain Keegan

Classifications

• B65H5/10

  Reciprocating or oscillating grippers {, e.g. suction or gripper tables} · CPC title

• B29C31/08

  of preforms {to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors (B29C31/066, B29C37/001, B29C43/085 take precedence)} · CPC title

• B65H2701/1938

  Veneer sheet · CPC title

• B25J15/0616

  with vacuum · CPC title

• B29C70/38 Primary

  Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} · CPC title