Patent Application
20070189884
1. Field of the Invention
This invention relates to a tool used for handling multiple length composite fuselage sections with integrated related tooling and used to assist with trim and Non Destructive Inspection (NDI) operations.
2. Background
Aircraft manufacturing technology has advanced to the state where the creation of a very large one piece aircraft composite fuselage section creating load requirements of near 50,000 lbs is possible.
These unique airplane fuselage sections have driven a need for proper handling equipment. For example, in test programs for large aircraft composite fuselage sections, a need has arisen for a tool capable of supporting, positioning and transporting large composite fuselage sections of varying lengths, while the sections are integrated with layup tools and internal support tooling. The sections must be supported and positioned while being transported throughout a factory and while being moved in and out of an autoclave. Heretofore, such large transport tools were not necessary since the manufacture of large composite fuselage sections was not done.
The present invention provides a tool capable of supporting, positioning and transporting large composite fuselage sections of varying lengths. Moreover, the tool of the present invention is capable of supporting, positioning and transporting the sections throughout a factory and while being moved in and out of an autoclave, with integrated layup tools and internal support tooling.
In an aspect of the invention, a transportation tool is provided which includes a first structural tower, and a second structural tower. A first structural frame member and a second structural frame member are used to secure the first structural tower to the second structural tower to support a payload. The first and second structural frame members define vacuum chamber accumulators.
In another aspect of the invention, a transportation tool is provided for transporting a single composite aircraft fuselage section. The tool includes a first spindle weldment mounted on a first structural tower, and a second spindle weldment mounted on a second structural tower, the spindle weldments are configured to couple the single composite aircraft fuselage section to the first and second structural towers. Also included is a first gimbal assembly configured to allow the first spindle weldment to move independent of the first structural tower, and a second gimbal assembly configured to allow the second spindle weldment to move independent of the second structural tower. The tool further includes a first structural frame member and a second structural frame member for securing the first structural tower to the second structural tower. The first and second structural frame members define vacuum chamber accumulators.
In yet another aspect of the invention, a method is provided for manufacture of a one-piece composite aircraft fuselage which includes loading a composite fuselage into a support structure; performing vacuum bagging operations on the composite fuselage; and maintaining vacuum integrity of the bagged composite fuselage for processing in an autoclave using vacuum accumulators integrated into the support structure.
Additional objects and features of the invention will be set forth in part in the detailed description which follows. It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed.
The accompanying drawings are included to provide further understanding of the invention, illustrate various embodiments of the invention, and together with the description serve to explain the principles and operation of the invention. In the drawings, the same components have the same reference numerals. The illustrated embodiment is intended to illustrate, but not to limit the invention. The drawings include the following Figures:
Payload 102 is manufactured using well known composite manufacturing techniques using tape layup processes that require the use of an autoclave to cure the composite material. Accordingly, tool 100 is capable of enduring adverse environments such as those generated by an autoclave, for example, elevated temperature of 450 degrees F. and elevated pressures of 90 psi. Tool 100 may be used to support and transport payload 102 from an area including a tape layup machine to an area housing the autoclave. Tool 100 may be required to support payload 102 in the environment created by the autoclave for the duration of a cure cycle. Tool 100 may then be used to transport payload 102 to non-destructive inspection (NDI) and Trim area.
After tool 100 has been used to support payload 102 throughout the composite layup and curing process, tool 100 may then be used in conjunction secondary support tooling to transport payload 102 to a location which may be, for example, as far as two miles away. As described below, tool 100 includes features to minimize deflection in payload 102 caused by dynamic load effects experienced during the entire transport sequence.
The supported payload 102 indexes to spindle weldments 210 and 212 with a receptacle 302 (
After indexing payload 102, mandrel 104, supporting payload 102, and tool 100 may then be bolted at spindle weldments 210 and 212, for example, along the bolt pattern 304 shown in
As shown in
Tool 100 experiences various transportation routes. For example, the uncured payload 102 is transported from the layup area to the cure area. The post cure payload 102 is transported from the cure area to the trim, test and assembly area. The trimmed payload 102 is transported from the trim/assembly area across roadways (which can include railroad tracks) to various other locations, such as a paint hanger. All of these moves cause payload 102 to experience dynamic effects created by rough and uneven surfaces. As a result, the relative position of first tower 202 and second tower 204 see movement, deflection, racking and vibration. Undesirable loads, deflections, racking or vibrations can be transferred into and become detrimental to the production payload 102. For example, wrinkles may develop in the pre-cured payload 102 when moving it from the layup area to the cure area.
In accordance with an embodiment of the present invention, gimbal assemblies 214 and 216 are incorporated into tool 100 to reduce the effect of the undesirable loads. Gimbal assemblies 214 and 216 minimize induced deflections of the pre-cured and post cured payload 102 (i.e. composite fuselage section) as well as provide bearings for support and rotation.
Gimbal assemblies 214 and 216 allow payload 102 to be supported independent of the deflections experienced by tool 100. Gimbal assemblies 214 and 216 allow payload 102 and spindle weldments 210 and 212 to rotate about longitudinal axis 502x, lateral horizontal axis 502y, and vertical axis 502z using, for example, a set of roller bearings.
As best illustrated in
As shown in
In one embodiment, drive system 222 is pneumatically powered. For example, drive system 222 may operate with shop supplied air routed thru a control box. In one embodiment, as shown in
In one embodiment, drive system 222 rotates payload 102 both in the clockwise and counterclockwise directions. When motor 306 is powered “on”, pneumatic disk brake 602 is disengaged.
When motor 306 is powered “off”, pneumatic disk brake 602 engages. Once payload 102 comes to rest, pneumatic disk brake 602 prevents payload 102 from any undesirable rotation. In one embodiment, disk brake 602 may resist up to 16600 ft-lbs of torque, including mandated factors of safety. In one embodiment, air motor 306 and disk brake 602 are removable from tool 100 so that air motor 306 and disk brake 602 may not be exposed to the autoclave environment. Once the autoclave operations are complete, motor 306 and brake 602 may be reinstalled.
In one operational example, the power and braking systems may be expected to turn and stop an unbalanced payload 102 of up to 8,333 ft-lbs of torque. In this example, payload 102 is a composite fuselage section. Due to layup tool manufacturing and layup variability, a 50 kip load could vary from the theoretical axis of rotation by up to 2 in. Also; different geometries of fuselage sections can add to the generation of off balanced loads. The integrated power and braking systems, reduce the risk to personnel and property.
It is undesirable for an unbalanced payload 102 to spool freely. The prevention of spooling may be controlled by applying back pressure to the air motor. However, air motors that withstand the amount of load contemplated in this example are not known to be available.
Since the system is pneumatically powered, it functions such that when the air is on, motor 306 turns and brake 602 is disengaged. In one embodiment, to power air motor 306 an operator must physically hold the control knob to an “on” position. When the air is off, motor 306 ceases operation and a spring loaded brake 602 is applied. Brake 602 is disengaged with air pressure and engaged by releasing the air pressure in order to activate the spring mechanism.
Alternatively, a set of lock pins as shown in
As shown in
As shown in
Typically, vacuum accumulators are a separate independent system attached to transport tools. In accordance with the present invention, integrated parts of tool 100, namely hollow side rails 206 and 208, are used as vacuum accumulators. This adaptation reduces tooling costs.
Vacuum accumulators 206 and 208 are used to hold vacuum on bagged payload 102 while payload 102 is being transported, for example, from the layup area to the curing area. The integrated vacuum system may also be used after cure to transport payload 102 to the NDI and trim area.
If vacuum loss should occur during transport, pieces of payload 102, such as caul plates and the like could dislodge and cause significant damage.
In one embodiment, once all air is pumped out of side rail chambers 206 and 208, hoses are disconnected from valves leaving side rail chambers 206 and 208, now charged with negative pressure. When needed in the transport process, hoses can be reconnected from side rail chambers 206 and 208 to bagged payload 102. In this embodiment, bagged payload 102 has previously had all air evacuated from it and sealed. When bagged payload 102 is connected via the hoses to side rail chambers 206 and 208, the valves are opened so that the vacuum pressure in side rail chambers 206 and 208 is transferred to bagged payload 102. In this manner, vacuum pressure can be maintained on bagged payload 102 such that any leaking in the bag system is overcome and bagged payload 102 can be safely held together and transported.
As best shown in
To shuttle payload 102 in and out of the autoclave, spring loaded swivel casters 218 are removed from each tower 202 and 204. Towers 202 and 204 are equipped with jack support points to raise and lower the towers. Using the jack supports, tool 100 is lowered on to a different set of casters 220, referred to as autoclave casters 220. Each tower 202 and 204 can have at least six autoclave casters 220. Each autoclave casters 220 may have a raised ridge circumventing the caster which coordinates to recessed floor mounted steel tracks.
Again referring to
Accordingly, the scope of the present invention should not be limited to the particular embodiments illustrated and described herein, as they are merely exemplary in nature, but rather, should be fully commensurate with that of the claims appended hereafter and their functional equivalents.
