Method and apparatus for layup placement

Patent metadata

Field	Value
Publication number	US-9770871-B2
Application number	US-75192807-A
Country	US
Kind code	B2
Filing date	May 22, 2007
Priority date	May 22, 2007
Publication date	Sep 26, 2017
Grant date	Sep 26, 2017

Abstract

Method and apparatus for layup placement on a layup structure is provided. The method includes iteratively loading a layup for the layup structure on a support frame of a saddle module; aligning the saddle module with a pre-selected registration position corresponding to a predetermined application path on the layup structure; and impressing the layup into forced contact with the layup structure along the predetermined application path using a predetermined application force. The apparatus includes a plurality of saddle modules configured to operate in unison, wherein the plurality of saddle modules is configured to receive a pre-selected composite material layup.

First claim

We claim:

1. A method for a placement of a composite material on an airframe, comprising:
placing the composite material on a saddle module, wherein the saddle module comprises:
a saddle base;
a locator arm pivotally attached to the saddle base;
a locator motive assembly connected to the saddle base and to the locator arm and configured to pivot the locator arm in a local Y-Z plane relative to the saddle base; and
a force applicator assembly connected to the locator arm, the force applicator assembly configured to move along an axis normal to the locator arm and further configured to apply the composite material to a curvilinear surface of the airframe, wherein the force applicator assembly further comprises a truck connected to the locator arm, wherein a roller is connected to an end of the truck, and wherein the truck is further configured to move in a direction normal to the locator arm in order to apply a force; and

affixing, using the force applicator, a first side of the composite material to the curvilinear surface of the airframe by progressively applying at least one moving region of pressure to a second side of the composite material along a curvilinear application path; and
moving the truck in the direction normal to the locator arm during affixing.

2. The method of claim 1 , further comprising:
aligning the saddle module with a pre-selected position, wherein the pre-selected position corresponds to a start of the curvilinear application path on the curvilinear surface of the airframe.

3. The method of claim 2 , wherein the locator arm comprises a first locator arm and a second locator arm disposed beside each other, and wherein the first locator arm and the second locator arm are spaced to define the moving region of pressure while traversing the curvilinear application path on the curvilinear surface of the airframe.

4. The method of claim 1 , wherein the airframe is for an aircraft assembled by a production process, comprising:
a pre-production phase;
a production phase; and
a post production phase.

5. The method of claim 4 , wherein the pre-production phase further comprises:
selecting a component, fabricated by a third party, used in an aircraft assembly and an aircraft sub-assembly.

6. The method of claim 4 , wherein the pre-production phase further comprises:
designing the airframe for placement of the composite material.

7. The method of claim 6 , wherein the post production phase further comprises:
rework of an aircraft using the composite material for the airframe during one of a delivery phase, a qualification phase, a maintenance phase, and a service phase.

8. The method of claim 1 , wherein the composite material includes a layup kit with a prepatterned composite structure tailored for application to a predetermined portion of the airframe.

9. A method for layup placement on an aircraft layup structure, comprising:
iteratively loading a layup for the aircraft layup structure on a support frame of a saddle module, wherein the saddle module comprises:
a saddle base;
a locator arm pivotally attached to the saddle base;
a locator motive assembly connected to the saddle base and to the locator arm and configured to pivot the locator arm in a local Y-Z plane relative to the saddle base; and
a force applicator assembly connected to the locator arm, the force applicator assembly configured to move along an axis normal to the locator arm and further configured to apply the layup to a curvilinear surface of the aircraft layup structure, wherein the force applicator assembly further comprises a truck connected to the locator arm, wherein a roller is connected to an end of the truck, and wherein the truck is further configured to move in a direction normal to the locator arm in order to apply a force;

aligning the saddle module with a pre-selected registration position corresponding to a curvilinear application path on a curvilinear surface of the aircraft layup structure; and
impressing, using the force applicator, a first side of the layup into a forced contact with a curvilinear surface of the aircraft layup structure by progressively applying at least one moving region of pressure to a second side of the layup along the curvilinear application path, wherein a laid-up structure is formed; and
moving the truck in the direction normal to the locator arm during impressing.

10. The method of claim 9 , further comprising:
prior to impressing the layup, indexing the layup to a pre-selected indexed position on the layup structure in a local frame of reference corresponding to the curvilinear application path.

11. The method of claim 10 , wherein impressing the layup further comprises:
impressing the layup from a first selectable indexed position on the aircraft layup structure to a second selectable indexed position.

12. The method of claim 11 , wherein the aircraft layup structure has a respective layup structure contour profile corresponding to the curvilinear application path, wherein the layup comprises a pre-selected layup corresponding to the respective contour profile, and wherein impressing the layup further comprises impressing a predetermined application force as a generally uniform moving region of application pressure, wherein the pre-selected layup is placed on a pre-selected indexed position on the layup structure and wherein the generally uniform moving region of application pressure is defined by one or more rollers, operably coupled to the saddle module, traversing the curvilinear application path.

13. The method of claim 12 , wherein verifying a layup application further comprises inspecting a layup position.

14. The method of claim 12 , wherein verifying a layup application further comprises inspecting the layup application.

15. The method of claim 9 , further comprising:
an aircraft assembly process utilizing the laid-up structure.

16. The method of claim 15 , wherein the aircraft assembly process further comprises:
a pre-production phase;
a production phase; and
a post production phase.

17. The method of claim 16 , wherein the pre-production phase further comprises:
selecting a component fabricated by a third party and the component is used in an aircraft assembly and an aircraft sub-assembly.

18. The method of claim 16 , wherein the pre-production phase further comprises:
designing the layup structure for the layup placement.

19. The method of claim 18 , wherein the post production phase further comprises:
rework of an aircraft using the layup for the layup structure during one of a delivery phase, a qualification phase, a maintenance phase and a service phase.

20. The method of claim 1 further comprising:
pivoting the locator arm in the local Y-Z plane during affixing.

21. The method of claim 1 , wherein affixing further comprises:
rolling the at least one roller along the composite material and against the airframe while the force applicator assembly applies the force during affixing.

22. The method of claim 9 further comprising:
pivoting the locator arm in the local Y-Z plane during impressing.

23. The method of claim 9 , wherein impressing further comprises:
rolling at least one roller along the layup and against an airframe while the force applicator assembly applies force during impressing.

Assignees

• Brennan Joseph D
• Hempstead George D
• Jones Darrell D
• Lum Matthew K
• Mccowin Peter D
• Rowe Terrence J
• Schlosstein Hugh R
• Boeing Co

Inventors

• Brennan Joseph D
• Hempstead George D
• Jones Darrell D
• Lum Matthew K
• Mccowin Peter D
• Rowe Terrence J
• Schlosstein Hugh R

Classifications

• B29C70/32

  on a rotating mould, former or core · CPC title

• B29L2031/3076

  Aircrafts (blades, propellers B29L2031/08) · CPC title

• Y10T29/49622

  Vehicular structural member making · CPC title

• Y10T29/53

  Means to assemble or disassemble · CPC title

• B29C70/541

  Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30) · CPC title