Patent Grant
9149909
1. Technical Field
The present invention relates to a manufacturing method for a stringer (longeron), for example, a stringer used as a reinforcing member for an aircraft main wing.
2. Description of the Related Art
For stringers used as reinforcing members for aircraft main wings, for example, there is a known stringer made of carbon fiber reinforced plastic (CFRP) disclosed in Japanese Unexamined Patent Application, Publication No. 2003-53851.
When a stringer used as a reinforcing member for an aircraft main wing is manufactured, it may be necessary to machine the wing tip portion thereof into a shape, for example, as shown in
Thus, there are problems in that the number of processes is increased, which deteriorates the productivity, and, when the circular saw is moved, carbon fiber reinforced plastic powder scatters about, which deteriorates the working environment of workers.
There is also a problem in that the blade of the drill or the teeth of the circular saw become blunt in a relatively short time, which increases the manufacturing costs.
The present invention has been made in view of the above-described circumstances, and an object thereof is to provide a stringer manufacturing method capable of enhancing the productivity, of improving the working environment of workers, and of reducing the manufacturing costs.
The present invention employs the following solutions in order to solve the above-described problems.
According to the present invention, there is provided a stringer manufacturing method for machining one end portion of an elongated member that is provided with a cap flange, a web, and a base flange and that has an inverted T-shape in a front view, an I-shape in a front view, or a T-shape in a front view into a desired shape to obtain a desired stringer, in which the one end portion of the elongated member is machined into a desired shape by using a vertical articulated robot that has at least 6 axes and that has, at the tip of an arm, an abrasive nozzle assembly that injects ultrahigh-pressure water containing abrasive and a catcher cup that recovers the ultrahigh-pressure water ejected from the abrasive nozzle assembly.
According to the stringer manufacturing method of the present invention, one end portion of the elongated member is automatically machined into a desired shape by the vertical articulated robot that has at least 6 axes, without using tools (a drill, a circular saw, etc.) and guiding jigs, which are conventionally used.
Thus, it is possible to enhance the productivity, to improve the working environment of workers, and to reduce manufacturing costs.
According to the present invention, there is provided a stringer manufacturing method for machining one end portion of an elongated member that is provided with a cap flange, a web, and a base flange and that has an inverted T-shape in a front view, an I-shape in a front view, or a T-shape in a front view into a desired shape to obtain a desired stringer, in which the one end portion of the elongated member is machined into a desired shape by using a vertical articulated robot that has at least 6 axes and that has, at the tip of an arm, an abrasive nozzle assembly that injects ultrahigh-pressure water containing abrasive, a catcher cup that recovers the ultrahigh-pressure water injected from the abrasive nozzle assembly, and a space adjustment mechanism that adjusts the space between the abrasive nozzle assembly and the catcher cup so as to maintain the space between the catcher cup and the elongated member constant.
According to the stringer manufacturing method of the present invention, one end portion of the elongated member is automatically machined into a desired shape by the vertical articulated robot that has at least 6 axes, without using tools (a drill, a circular saw, etc.) and guiding jigs, which are conventionally used.
Thus, it is possible to enhance the productivity, to improve the working environment of workers, and to reduce manufacturing costs.
According to the stringer manufacturing method of the present invention, the distance between the catcher cup and the elongated member, more specifically, the distance between the inlet of the catcher cup and a surface of the elongated member, is kept (maintained) (substantially) constant.
Thus, it is possible to easily recover ultrahigh-pressure water containing abrasive, to produce a smooth machined surface, thus eliminating a finishing process, and to further enhance the productivity.
According to the stringer manufacturing method of the present invention, all of the ultrahigh-pressure water containing abrasive is recovered.
Thus, it is possible to maintain the moving speed (specifically, cutting speed) of the abrasive nozzle assembly and the catcher cup constant and to further enhance the productivity.
The above-described stringer manufacturing method more preferably includes the steps of: when the one end portion of the elongated member having the inverted T-shape in a front view is to be machined into a desired shape, cutting off a one-lateral-side portion of the cap flange and an upper end portion of the web that are located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at one lateral side of the elongated member such that the abrasive nozzle assembly is located higher than the cap flange and the catcher cup is located lower than the cap flange, and disposing the abrasive nozzle assembly so as to be located closer to the central axis of the elongated member than the catcher cup is; cutting off an other-lateral-side portion of the cap flange and an upper end portion of the web that are located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at the other lateral side of the elongated member such that the abrasive nozzle assembly is located higher than the cap flange and the catcher cup is located lower than the cap flange, and disposing the abrasive nozzle assembly so as to be located closer to the central axis of the elongated member than the catcher cup is; and cutting off a portion of the web that is located at the one end portion of the elongated member, after locating the catcher cup at one lateral side of the web, after locating the abrasive nozzle assembly at the other lateral side of the web, and disposing the abrasive nozzle assembly and the catcher cup such that the central axis thereof is parallel to an upper surface of the cap flange and a lower surface of the base flange.
According to this stringer manufacturing method, the distance between the abrasive nozzle assembly and the elongated member, more specifically, the distance between the outlet of the abrasive nozzle assembly and a surface of the elongated member, is kept (maintained) (substantially) constant.
Thus, it is possible to produce a smooth machined surface, thus eliminating a finishing process, and to further enhance the productivity.
The above-described stringer manufacturing method more preferably includes the steps of: when the one end portion of the elongated member having the I-shape in a front view is to be machined into a desired shape, cutting off a one-lateral-side portion of the base flange and a lower end portion of the web that are located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at one lateral side of the elongated member such that the abrasive nozzle assembly is located lower than the base flange and the catcher cup is located higher than the base flange, and disposing the abrasive nozzle assembly so as to be located closer to the central axis of the elongated member than the catcher cup is; cutting off an other-lateral-side portion of the base flange and a lower end portion of the web that are located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at the other lateral side of the elongated member such that the abrasive nozzle assembly is located lower than the base flange and the catcher cup is located higher than the base flange, and disposing the abrasive nozzle assembly so as to be located closer to the central axis of the elongated member than the catcher cup is; cutting off a portion of the web that is located at the one end portion of the elongated member, after locating the catcher cup at one lateral side of the web, after locating the abrasive nozzle assembly at the other lateral side of the web, and disposing the abrasive nozzle assembly and the catcher cup such that the central axis thereof is parallel to an upper surface of the cap flange and a lower surface of the base flange; cutting off both corner portions of the cap flange that are located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at the one lateral side of the elongated member such that the abrasive nozzle assembly is located lower than the cap flange and the catcher cup is located higher than the cap flange, and disposing the abrasive nozzle assembly and the catcher cup such that the central axis thereof is parallel to a one-lateral-side surface and an other-lateral-side surface of the web; and cutting off a remaining portion of the cap flange that is located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at the one lateral side of the elongated member such that the abrasive nozzle assembly is located higher than the cap flange and the catcher cup is located lower than the cap flange, and disposing the abrasive nozzle assembly and the catcher cup such that the central axis thereof is parallel to the one-lateral-side surface and the other-lateral-side surface of the web.
The above-described stringer manufacturing method more preferably includes the steps of: when the one end portion of the elongated member having the T-shape in a front view is to be machined into a desired shape, cutting off a one-lateral-side portion of the base flange and a lower end portion of the web that are located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at one lateral side of the elongated member such that the abrasive nozzle assembly is located lower than the base flange and the catcher cup is located higher than the base flange, and disposing the abrasive nozzle assembly so as to be located closer to the central axis of the elongated member than the catcher cup is; cutting off an other-lateral-side portion of the base flange and a lower end portion of the web that are located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at the other lateral side of the elongated member such that the abrasive nozzle assembly is located lower than the base flange and the catcher cup is located higher than the base flange, and disposing the abrasive nozzle assembly so as to be located closer to the central axis of the elongated member than the catcher cup is; cutting off a portion of the web that is located at the one end portion of the elongated member, after locating the catcher cup at one lateral side of the web, and locating the abrasive nozzle assembly at the other lateral side of the web, and disposing the abrasive nozzle assembly and the catcher cup such that the central axis thereof is parallel to an upper surface of the cap flange and a lower surface of the base flange; and cutting off a portion of the cap flange that is located at the one end portion of the elongated member, after disposing the abrasive nozzle assembly and the catcher cup at the one lateral side of the elongated member such that the abrasive nozzle assembly is located higher than the cap flange and the catcher cup is located lower than the cap flange, and disposing the abrasive nozzle assembly and the catcher cup such that the central axis thereof is parallel to a one-lateral-side surface and an other-lateral-side surface of the web.
According to one of the above-described stringer manufacturing methods, the distance between the abrasive nozzle assembly and the elongated member, more specifically, the distance between the outlet of the abrasive nozzle assembly and a surface of the elongated member, is kept (maintained) (substantially) constant.
Thus, it is possible to produce a smooth machined surface, thus eliminating a finishing process, and to further enhance the productivity.
According to one of the above-described stringer manufacturing methods, the base flange is machined prior to the cap flange, and cutting chips fall to the lower side without being accumulated on the base flange. Thus, when the cap flange is machined, the movements of the abrasive nozzle assembly and the catcher cup are not blocked by the cutting chips accumulated on the base flange.
Thus, it is possible to efficiently machine the elongated member and to further enhance the productivity.
According to the stringer manufacturing method of the present invention, an advantage is afforded in that it is possible to enhance the productivity, to improve the working environment of workers, and to reduce manufacturing costs.
Stringer (longeron) manufacturing methods according to the present invention will be described below with reference to
The stringer manufacturing methods of the present invention are performed by using a 6-axis robot (vertical articulated robot) 1 shown in
Ultrahigh-pressure water containing abrasive (abrading agent) is ejected from an outlet 14a of the abrasive nozzle assembly 14 that faces an inlet 15a of the catcher cup 15. The ultrahigh-pressure water containing abrasive ejected from the outlet 14a of the abrasive nozzle assembly 14 is recovered by the catcher cup 15 via the inlet 15a. The height dimension (the length in the vertical direction (up and down direction in
The stringer manufacturing methods of the present invention are used to machine, for example, one end portion of an elongated member (a wing tip portion if the stringer constitutes an aircraft main wing) with a cross-sectional shape shown in
First, a description will be given of a stringer manufacturing method according to a first embodiment of the present invention, in which the 6-axis robot 1 is used to machine one end portion of an elongated member 21 shown in
The elongated member 21 is made, for example, of carbon fiber reinforced plastic (CFRP), which is formed by combining carbon fibers and plastic. As shown in
The elongated member 21 is secured to special jigs (not shown), and the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the one-lateral-side portion of the cap flange 23 and the upper end portion of the web 24 located at one end portion of the elongated member 21 have been cut off, the injection of ultrahigh-pressure water containing abrasive is stopped, and the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the other-lateral-side portion of the cap flange 23 and the upper end portion of the web 24 located at one end portion of the elongated member 21 have been cut off, the injection of ultrahigh-pressure water containing abrasive is stopped, and the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
The thus-formed stringer 22 (see
According to the stringer manufacturing method of this embodiment, machining of one end portion of the elongated member 21 into a desired shape is automatically performed by the 6-axis robot 1, without using tools (a drill, a circular saw, etc.) and guiding jigs, which are conventionally used.
Thus, it is possible to enhance the productivity, to improve the working environment of workers, and to reduce manufacturing costs.
According to the stringer manufacturing method of this embodiment, the distance between the abrasive nozzle assembly 14 and the elongated member 21, more specifically, the distance between the outlet 14a of the abrasive nozzle assembly 14 and a surface of the elongated member 21, is kept (maintained) (substantially) constant.
Thus, it is possible to produce a smooth machined surface, thus eliminating a finishing process, and to further enhance the productivity.
Next, a description will be given of a stringer manufacturing method according to a second embodiment of the present invention, in which the 6-axis robot 1 is used to machine one end portion of the elongated member 21 shown in
As in the above-described embodiment, the elongated member 21 is secured to special jigs (not shown), and the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
Since the abrasive nozzle assembly 14 is disposed closer to the other end of the elongated member 21 than the catcher cup 15 is, the cut end of the cap flange 23 is made slanted, as shown in
After the one-lateral-side portion of the cap flange 23 and the upper end portion of the web 24 located at one end portion of the elongated member 21 have been cut off, the injection of ultrahigh-pressure water containing abrasive is stopped, and the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the other-lateral-side portion of the cap flange 23 and the upper end portion of the web 24 located at one end portion of the elongated member 21 have been cut off, the injection of ultrahigh-pressure water containing abrasive is stopped, and the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in the state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
The thus-formed stringer 32 (see
Since the functional effects of this embodiment are the same as those of the above-described first embodiment, a description thereof will be omitted.
Next, a description will be given of a stringer manufacturing method according to a third embodiment of the present invention, in which the 6-axis robot 1 is used to machine one end portion of an elongated member 51 shown in
The elongated member 51 is made, for example, of carbon fiber reinforced plastic (CFRP), which is formed by combining carbon fibers and plastic. As shown in
As in the above-described embodiments, the elongated member 51 is secured to special jigs (not shown), and the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the one-lateral-side portion of the base flange 55 and the lower end portion of the web 54 located at one end portion of the elongated member 51 have been cut off, the injection of ultrahigh-pressure water containing abrasive is stopped, and the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the portion of the base flange 55 located at one end portion of the elongated member 51 has been cut off, the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the portion of the web 54 located at one end portion of the elongated member 51 has been cut off, the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After both the corner portions of the cap flange 53 located at one end portion of the elongated member 51 have been cut off, the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in a state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
The thus-formed stringer 52 (see
According to the stringer manufacturing method of this embodiment, because the base flange 55 is machined prior to the cap flange 53, and cutting chips fall to the lower side, without being accumulated on the base flange 55, when the cap flange 53 is machined, the movements of the abrasive nozzle assembly 14 and the catcher cup 15 are not blocked by the cutting chips accumulated on the base flange 55.
Therefore, it is possible to efficiently machine the elongated member 51 and to further enhance the productivity.
Since the other functional effects are the same as those of the above-described embodiment, a description thereof will be omitted.
Finally, a description will be given of a stringer manufacturing method according to a fourth embodiment of the present invention, in which the 6-axis robot 1 is used to machine one end portion of an elongated member 71 shown in
The elongated member 71 is made, for example, of carbon fiber reinforced plastic (CFRP), which is formed by combining carbon fibers and plastic. As shown in
As in the above-described embodiments, the elongated member 71 is secured to special jigs (not shown), and the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the one-lateral-side portion of the base flange 75 and the lower end portion of the web 74 located at one end portion of the elongated member 71 have been cut off, the injection of ultrahigh-pressure water containing abrasive is stopped, and the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in the state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the portion of the base flange 75 located at one end portion of the elongated member 71 has been cut off, the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in the state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
After the portion of the web 74 located at one end portion of the elongated member 71 has been cut off, the abrasive nozzle assembly 14 and the catcher cup 15 are then disposed in the state shown in
After the abrasive nozzle assembly 14 and the catcher cup 15 are disposed at the predetermined positions, specifically, after the abrasive nozzle assembly 14 and the catcher cup 15 are disposed in the state shown in
The thus-formed stringer 72 (see
Since the functional effects of this embodiment are the same as those of the above-described third embodiment, a description thereof will be omitted.
The present invention is not limited to the above-described embodiments, and various changes and modifications can be made without departing from the scope of the present invention.
In the above-described embodiments, it is more preferable that the 6-axis robot 1 be provided with a space adjustment mechanism (not shown) that adjusts the space between the abrasive nozzle assembly 14 and the catcher cup 15 such that the space between the catcher cup 15 and the elongated member 21, 51, or 71 is maintained constant, for example, such that L2 and L3 in
As the space adjustment mechanism, a longitudinal motion mechanism that can move in a direction indicated by a white arrow in
In a case where the space adjustment mechanism is not provided, L1 in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2009-237334 | Oct 2009 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2010/067954 | 10/13/2010 | WO | 00 | 4/3/2012 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2011/046142 | 4/21/2011 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20120184185 A1 | Jul 2012 | US |
