System, method, and apparatus for use in ply compaction in forming a composite structure

Patent metadata

Field	Value
Publication number	US-2021107242-A1
Application number	US-201916601094-A
Country	US
Kind code	A1
Filing date	Oct 14, 2019
Priority date	Oct 14, 2019
Publication date	Apr 15, 2021
Grant date	—

Abstract

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a chassis at a first location along a length dimension of the forming tool, selectively rotating a flange forming device, that is coupled to the chassis, about a yaw axis based on a relative orientation of the flange forming device to the at least one flange surface, applying, with the flange forming device, the ply of material onto the forming tool, moving the chassis relative to the forming tool to position the chassis at a second location along the length dimension of the forming tool, and repeating the selective rotation and the application steps at the second location.

First claim

What is claimed is:

1 . A method for use in ply compaction in forming a composite structure, the method comprising:
positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface; positioning a chassis at a first location along a length dimension of the forming tool; selectively rotating a flange forming device, that is coupled to the chassis, about a yaw axis based on a relative orientation of the flange forming device to the at least one flange surface; applying, with the flange forming device, the ply of material onto the forming tool; moving the chassis relative to the forming tool to position the chassis at a second location along the length dimension of the forming tool; and repeating the selective rotation and the application steps at the second location to form the composite structure.

2 . The method in accordance with claim 1 , wherein the flange forming device has a forming head configured to apply pressure to the ply of material, the forming head having a first end and a second end, wherein selectively rotating a flange forming device comprises:
determining a relative distance of the first end and the second end to the at least one flange surface; and holding the flange forming device in a selected rotational orientation, that is determined based on the relative distance of each of the first end and the second end to the at least one flange surface, to maintain parallelism with the at least one flange surface.

3 . The method in accordance with claim 2 , wherein the forming head is movable in a predefined range of motion, wherein applying the ply of material comprises moving the forming head along the predefined range of motion to apply pressure continuously across the web surface and the at least one flange surface.

4 . The method in accordance with claim 3 , wherein moving the forming head comprises maintaining contact with the ply of material as the forming head moves across the web surface, an interface defined between the web surface and the at least one flange surface, and the at least one flange surface.

5 . The method in accordance with claim 1 , wherein positioning a ply of material comprises providing the ply of material to the forming tool from a ply distribution apparatus.

6 . The method in accordance with claim 1 further comprising selectively rotating the flange forming device about a pitch axis that is perpendicular to the yaw axis and the length dimension.

7 . An apparatus for use in ply compaction in forming a composite structure, the apparatus comprising:
a forming tool comprising a web surface and at least one flange surface extending from the web surface, wherein the forming tool comprises a length dimension; a chassis extending over the forming tool, wherein the chassis is movable relative to the forming tool along the length dimension; and at least one flange forming device coupled to the chassis, wherein the at least one flange forming device is rotatable relative to the chassis about a yaw axis based on a relative orientation of the at least one flange forming device to the at least one flange surface.

8 . The apparatus in accordance with claim 7 further comprising a bearing plate coupled between the chassis and the at least one flange forming device, the bearing plate comprising at least one mounting surface configured to receive the at least one flange forming device, and an actuator coupled to the at least one mounting surface, wherein the actuator is configured to rotate the at least one mounting surface relative to the yaw axis.

9 . The apparatus in accordance with claim 7 , wherein the at least one flange forming device comprises:
a forming head configured to apply pressure to the web surface and the at least one flange surface; and a orientation sensor configured to determine a relative orientation of the forming head to the at least one flange surface, wherein the at least one flange forming device is rotatable based on the determined relative orientation.

10 . The apparatus in accordance with claim 9 , wherein the forming head is movable relative to the forming tool to apply pressure continuously across the web surface and then across the at least one flange surface.

11 . The apparatus in accordance with claim 9 , wherein the forming head comprises a first end and a second end, wherein the orientation sensor comprises a first sensor at the first end and a second sensor at the second end, the first sensor and the second sensor configured to determine a relative distance of the first end and the second end to the at least one flange surface.

12 . The apparatus in accordance with claim 8 , wherein the forming tool is contoured to define a variable radius of curvature in the at least one flange surface along the length dimension.

13 . The apparatus in accordance with claim 7 further comprising a ply distribution apparatus coupled to the chassis.

14 . An apparatus for use in ply compaction in forming a composite structure, the apparatus comprising:
a bearing plate comprising at least one mounting surface and an actuator coupled to the at least one mounting surface, wherein the actuator is configured to rotate the at least one mounting surface about a yaw axis; and a flange forming device coupled to, and rotatable with, the at least one mounting surface, the flange forming device comprising:
a forming head configured to apply pressure to a work surface; and
a orientation sensor configured to determine a relative orientation of the forming head to the work surface, wherein the actuator is configured to rotate the flange forming device based on the determined relative orientation.

15 . The apparatus in accordance with claim 14 , wherein the bearing plate further comprises a friction brake configured to engage the at least one mounting surface to hold the flange forming device in a selected rotational orientation.

16 . The apparatus in accordance with claim 14 , wherein the forming head comprises a plurality of holding members and a contact element extending across the plurality of holding members, wherein the plurality of holding members are each independently deflectable relative to each other.

17 . The apparatus in accordance with claim 14 , wherein the forming head comprises a first end and a second end, wherein the orientation sensor comprises a first sensor at the first end and a second sensor at the second end, the first sensor and the second sensor configured to determine a relative distance of the first end and the second end to the work surface.

18 . The apparatus in accordance with claim 14 , wherein the flange forming device further comprises a base, wherein the forming head is coupled, and movable relative, to the base

19 . The apparatus in accordance with claim 18 , wherein the forming head is movable in at least two dimensions relative to the base to define a predefined range of motion.

20 . The apparatus in accordance with claim 14 further comprising a pitch actuator configured to rotate the flange forming device about a pitch axis that is perpendicular to the yaw axis.

Assignees

• Boeing Co

Inventors

• Hopkins Andrew
• Harris Christopher Gary
• Henry John R
• Fisher Scott
• Conaty Jessica

Classifications

• B29K2105/0872

  Prepregs · CPC title

• B29C70/54

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title

• B29D99/0003

  Producing profiled members, e.g. beams · CPC title

• B29C70/30

  Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core · CPC title