System and method of manufacturing composite modules

Patent metadata

Field	Value
Publication number	US-9682523-B2
Application number	US-201414522776-A
Country	US
Kind code	B2
Filing date	Oct 24, 2014
Priority date	Oct 30, 2013
Publication date	Jun 20, 2017
Grant date	Jun 20, 2017

Abstract

A system for producing a fiber-reinforced composite module, such as a panel module, having an integrated stiffening structure for an aircraft or spacecraft includes a form core assembly station for assembling a plurality of form cores covered with reinforcing fiber layers to constitute at least one stiffening element of the integrated stiffening structure, a form core placement station which receives assembled form cores from the assembly station for placing or depositing the assembled form cores in or on a molding tool, and a turning station for rotating or inverting the assembled form cores. The turning station is configured to convey or transport the assembled form cores from the assembly station to the placement station. The turning station defines a path which is configured to rotate or invert the assembled form cores as they are conveyed or moved to the placement station.

First claim

The invention claimed is:

1. A turning apparatus for rotating or inverting a pre-assembly during manufacture of a fibre-reinforced composite module having an integrated stiffening structure,
wherein the apparatus is configured to convey or transport the pre-assembly from a first position, at which the pre-assembly is received by the apparatus, to a second position, at which the pre-assembly is discharged from the apparatus;
wherein the apparatus includes at least one track or rail defining a path from the first position to the second position;
wherein the apparatus is configured to convey or transport the pre-assembly along said at least one track or rail to the second position; and
wherein the path is configured to rotate or invert the pre-assembly as the pre-assembly is conveyed or transported to the second position.

2. The turning apparatus according to claim 1 , wherein the path is configured to rotate or invert the pre-assembly progressively as the pre-assembly conveyed or transported from the first position to the second position.

3. The turning apparatus according to claim 2 , wherein the path from the first position to the second position is at least partially curved or arcuate, and
wherein a centre of curvature of the curved or arcuate path corresponds to an axis of rotation for the pre-assembly as the pre-assembly is rotated or inverted.

4. A system for producing a fibre-reinforced composite module having an integrated stiffening structure for an aircraft or spacecraft, comprising:
a form core assembly station for assembling a plurality of form cores covered with reinforcing fibre layers to constitute at least one stiffening element for the integrated stiffening structure;
a form core placement station which receives assembled form cores from the assembly station for placing or depositing said assembled form cores in or on a moulding tool; and
a turning station for rotating or inverting the assembled form cores, wherein the turning station is configured to convey or transport the assembled form cores from the assembly station to the placement station, wherein the turning station defines a path configured to rotate or invert the assembled form cores as the assembled form cores are conveyed or transported to the placement station, and
wherein the turning station is configured to transport or convey the assembled form cores along a curved path defined by at least one track or rail to rotate or invert the assembled form cores before the assembled form cores are received in the placement station.

5. The system according to claim 4 ,
wherein a centre of curvature of the curved path or arc corresponds to an axis of rotation for the form cores.

6. The system according to claim 4 , wherein the placement station is configured to receive the assembled form cores from the turning station in one or more rows or linear arrays, wherein each row or linear array forms elements of the structure, and/or
wherein the placement station is configured to move between an upper position at which the assembled form cores are received from the turning station and a lower position at which the assembled form cores are placed or deposited in or on the moulding tool.

7. The system according to claim 4 , further comprising:
a reinforcing fibre application station for applying layers of reinforcing fibres to each of the plurality of form cores before the form cores are assembled at the assembly station;
wherein the system further includes a transport or conveying mechanism to transport or convey the form cores covered with reinforcing fibre layers to the assembly station from the application station.

8. The system according to claim 4 , wherein the assembly station is configured to assemble the plurality of form cores aligned in a row or a linear array to produce an elongate structural element for the integrated stiffening structure.

9. A method of manufacturing a fibre-reinforced composite module, with integrated stiffening structure for an aircraft or spacecraft, comprising:
assembling a plurality of form cores covered with reinforcing fibre layers at an assembly station to constitute one or more structural elements for the integrated stiffening structure; and
conveying or transporting the assembled form cores along a path defined by at least one track or rail from the assembly station to the placement station, wherein the path is configured to rotate or invert the assembled form cores as the assembled form cores are conveyed or transported to the placement station,
receiving assembled form cores at a placement station from the assembly station for placing or depositing said assembled form cores in or on a moulding tool; and
rotating or inverting the assembled form cores before the assembled form cores are received in the placement station.

10. The method according to claim 9 , wherein the assembled form cores are transported or conveyed along a curved path or through an arc to effect or cause the inversion before the assembled form cores are received in the placement station, a centre of curvature of the curved path or the arc corresponding to an axis of rotation for the assembled form cores.

11. The method according to claim 9 , wherein assembling comprises:
assembling the plurality of form cores aligned in one or more row or linear array; and/or
wherein receiving comprises: receiving the assembled form cores from the turning station in one or more rows or linear arrays, whereby each row or linear array is configured to form at least one element of the integrated stiffening structure.

Assignees

• Airbus Operations Gmbh

Inventors

• Engels Alexander
• Zahlen Pierre
• Meyer Lars

Classifications

• B29D99/0014 Primary

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