Caul plates for preforms that undergo pick and placement

Patent metadata

Field	Value
Publication number	US-11865798-B2
Application number	US-202016790409-A
Country	US
Kind code	B2
Filing date	Feb 13, 2020
Priority date	Feb 13, 2020
Publication date	Jan 9, 2024
Grant date	Jan 9, 2024

Abstract

Systems and methods are provided for facilitating pick and placement of preforms. One embodiment is a method for picking and placing a preform. The method includes placing an inner surface of a first caul plate into contact with a first side of a stringer preform, such that an outer surface of the first caul plate forms a first plane that is uniform along a length of the stringer preform, placing an inner surface of a second caul plate into contact with a second side of the stringer preform, such that an outer surface of the second caul plate forms a second plane that is parallel to the first plane along a length of the stringer preform, grasping the caul plates at the first plane and the second plane along the length of the stringer preform, and lifting the stringer preform together with the caul plates while maintaining the grasp.

First claim

What is claimed is:

1. A method for picking and placing a stringer preform that includes a web and flanges, wherein the web changes angle with respect to the flanges along a length of the stringer preform, the method comprising:
placing an inner surface of a first caul plate into contact with the web and a first flange on a first side of the stringer preform, wherein an outer surface of the first caul plate forms a first plane that is uniform along the length of the stringer preform; and
placing an inner surface of a second caul plate into contact with the web and a second flange on a second side of the stringer preform, wherein an outer surface of the second caul plate forms a second plane that is uniform along the length of the stringer preform and parallel to the first plane;
wherein the inner surface of the first caul plate is complementary to the first side of the stringer preform such that an angle of the inner surface of the first caul plate in relation to the outer surface of the first caul plate changes with the angle of the web along the length of the stringer preform;
wherein the inner surface of the second caul plate is complementary to the second side of the stringer preform such that an angle of the inner surface of the second caul plate in relation to the outer surface of the second caul plate changes with the angle of the web along the length of the stringer preform;
the method further comprising:
grasping the caul plates at the first plane and the second plane along the length of the stringer preform; and
lifting the stringer preform together with the caul plates while maintaining the grasp.

2. The method of claim 1 further comprising:
carrying the stringer preform and the caul plates to a new location.

3. The method of claim 1 wherein:
grasping the caul plates is performed via multiple end effectors disposed along the length of the stringer preform.

4. The method of claim 1 further comprising:
hardening the stringer preform while the caul plates enforce a shape onto the stringer preform.

5. The method of claim 4 further comprising:
removing the caul plates after hardening of the stringer preform into a composite part.

6. The method of claim 1 further comprising:
maintaining a shape of the stringer preform via the caul plates while lifting the stringer preform.

7. The method of claim 1 further comprising:
placing the stringer preform onto a wing panel preform; and
hardening the stringer preform with the wing panel preform while the caul plates enforce a shape onto the stringer preform.

8. The method of claim 1 further comprising:
applying adapters to at least one of the first side and the second side of the stringer preform to facilitate picking and placement of the stringer preform.

9. The method of claim 8 wherein:
applying the adapters comprises placing the adapters in series along the length of the stringer preform.

10. The method of claim 1 wherein:
lifting the stringer preform is performed via a Pick and Place (PNP) machine.

11. The method of claim 1 wherein:
grasping the caul plates comprises extending an end effector into position such that individual fingers of the end effector bridge a distance between the outer surfaces of the caul plates, and drawing the fingers together.

12. The method of claim 1 wherein:
grasping the caul plates is performed at a uniform pinch angle and thickness.

13. The method of claim 1 wherein:
the caul plates exhibit a non-uniform thickness.

14. A method for picking and placing a stringer preform that includes a web and flanges, wherein the web changes angle with respect to the flanges along a length of the stringer preform,
the method comprising:
placing an inner surface of a first caul plate into contact with the web and a first flange on a first side of the stringer preform, wherein an outer surface of the first caul plate forms a first plane that is uniform along the length of the stringer preform; and
placing an inner surface of a second caul plate into contact with the web and a second flange on a second side of the stringer preform, wherein an outer surface of the second caul plate forms a second plane that is uniform along the length of the stringer preform and is parallel to the first plane;
wherein the inner surface of the first caul plate is complementary to the first side of the stringer preform, and contacts the first side along the entire length of the stringer preform;
wherein the inner surface of the second caul plate is complementary to the second side of the stringer preform, and contacts the second side along the entire length of the stringer preform;
the method further comprising:
grasping the caul plates at the first plane and the second plane along the length of the stringer preform;
lifting and placing the stringer preform together with the caul plates while maintaining the grasp; and
hardening the stringer preform while the caul plates enforce a shape onto the stringer preform.

15. The method of claim 14 wherein:
placing the stringer preform comprises placing the stringer preform onto a wing panel preform; and
hardening the stringer preform comprises hardening the stringer preform with the wing panel preform while the caul plates enforce the shape onto the stringer preform.

16. The method of claim 14 further comprising:
removing the caul plates after hardening of the stringer preform into a composite part.

17. The method of claim 14 further comprising:
maintaining the shape of the stringer preform via the caul plates while lifting the stringer preform.

18. The method of claim 14 wherein:
grasping the caul plates is performed via multiple end effectors disposed along the length of the stringer preform.

19. The method of claim 14 wherein:
lifting the stringer preform is performed via a Pick and Place (PNP) machine.

20. The method of claim 14 wherein:
grasping the caul plates is performed at a uniform pinch angle and thickness.

21. The method of claim 14 wherein:
the caul plates exhibit a non-uniform thickness.

22. A method for picking and placing a stringer preform that includes a web and flanges, wherein the web changes angle with respect to the flanges along a length of the stringer preform, the method comprising:
placing an inner surface of a first caul plate into contact with the web and a first flange on a first side of the stringer preform, wherein an outer surface of the first caul plate forms a first plane that is uniform along the length of the stringer preform; and
placing an inner surface of a second caul plate into contact with the web and a second flange on a second side of the stringer preform, wherein an outer surface of the second caul plate forms a second plane that is uniform along the length of the stringer preform and parallel to the first plane;
wherein the inner surface of the first caul plate is complementary to the first side of the stringer preform such that an angle of the inner surface of the first caul plate in relation to the outer surface of the first caul plate changes with the angle of the web along the length of the stringer preform;
wherein the inner surface of the second caul plate is complementary to the second side of the stringer preform such that an angle of the inner surface of the second caul plate in relation to the outer surface of the second caul plate changes with the angle of the web along the length of the stringer preform.

23. The method of

Assignees

• Boeing Co

Inventors

• Ahn Jonathan Y
• Tran Davis

Classifications

• B64C1/064

  Stringers; Longerons · CPC title

• B29C70/84 Primary

  by moulding material on preformed parts to be joined {(joining plastic parts by moulding B29C65/70)} · CPC title

• B29C43/3642

  Bags, bleeder sheets or cauls for isostatic pressing · CPC title

• B29C65/481

  Non-reactive adhesives, e.g. physically hardening adhesives · CPC title

• B29C70/06

  Fibrous reinforcements only · CPC title