Patent Application
20240181725
The present disclosure relates generally to manufacturing composite structures. More specifically, the present disclosure relates to a trimming system used in manufacturing composite structures for aircraft applications.
Manufacturers use composite structures to provide light-weight and structurally sound parts for various applications. Increasing the efficiency of the composite manufacturing process is a priority for aircraft manufacturers. They seek to lower costs and increase the rate at which an aircraft is produced while minimizing the risk of rework or discarding of composite parts during the process.
In fabricating parts, composite structures are trimmed into desired configurations. Trimming may be a time-consuming and complex process. Some composite structures used for aircraft applications are 70+ feet in length. Orienting and moving such large structures about a manufacturing floor requires time, space, and manpower.
A composite structure may be trimmed into a desired part prior to or after curing using an ultrasonic knife. However, given the physics of an ultrasonic knife system, which is vibrations, the entire cutting process causes the composite structure being trimmed and the knife blade to increase in temperature. The heat may cause the resin of the composite structure to further flow out of the cut region which can act as a glue and cause the scrap trimmed from the cut part to heat weld back to the cut part before the resin can naturally cool and harden. When this happens, it is more difficult to separate the scrap from the desired part.
Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues.
An illustrative embodiment of the present disclosure provides trimming and scrap removal system for composite structures. The trimming and scrap removal system comprises an ultrasonic knife connected to a robotic arm. The ultrasonic knife is configured to trim an uncured composite structure along a path. The trimming and scrap removal system further comprise an ultrasonic parting horn connected to the robotic arm. The ultrasonic parting horn is configured to separate scrap from the uncured composite structure. A position of the ultrasonic parting horn relative to the ultrasonic knife is adjustable. The trimming and scrap removal system further comprises a web support connected to the robotic arm. A position of the web support relative to both the ultrasonic knife and the ultrasonic parting horn is adjustable.
Another illustrative embodiment of the present disclosure provides a method for trimming and removing scrap from a composite structure. An ultrasonic knife is positioned relative to an uncured composite structure and the ultrasonic knife is connected to a robotic arm. A parting horn is positioned relative to the ultrasonic knife and spaced from the uncured composite structure. The parting horn is connected to the robotic arm. The uncured composite structure is trimmed with the ultrasonic knife along a path. The scrap from the uncured composite structure is separated from the uncured composite structure with the parting horn along the path.
A further illustrative embodiment of the present disclosure provides a composite manufacturing system comprising a robotic arm and a trimming and scrap removal system for composite structures. The trimming and scrap removal system comprises an ultrasonic knife connected to the robotic arm and a parting horn connected to the robotic arm. The ultrasonic knife is configured to trim an uncured composite structure along path while the parting horn is configured to separate scrap from the uncured composite structure. A position of the parting horn relative to the ultrasonic knife is adjustable.
The features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings.
The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives and features thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein:
The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that current ultrasonic systems utilize either a gantry or tabletop bed with the use of a commercial, off the shelf ultrasonic trimming system. These solutions typically do not provide scrap removal or management other than manually removing the scrap.
The illustrative embodiments also recognize and take into account that during trimming of composite structures with an ultrasonic system, the trimmed part and the knife blade of the ultrasonic system may increase in temperature such that the resin of the composite structure being trimmed may bleed through the cut region and cause the scrap and the desired part to stick together. Essentially heat welding the scrap back to the trimmed part.
Thus, the disclosed embodiments provide a trimming and scrap removal system for composite parts having an ultrasonic knife connected to a robotic arm, an ultrasonic parting horn connected to the robotic arm, and a web support connected to the robotic arm. The ultrasonic knife is configured to trim an uncured composite structure along a path. The ultrasonic parting horn is configured to separate scrap from the uncured composite structure so that the scrap does not stick to the trimmed part. Composite structures may be trimmed prior to or after curing and multiple robots may move about the manufacturing environment to trim the composite structure at the same time.
With reference now to the figures and, in particular, with reference to
As depicted, composite manufacturing system 100 includes tool 104, robotic arm 106, and trimming and scrap removal system 110. Trimming and scrap removal system 110 is used to cut or trim composite material 112 in its uncured state and separate the scrap from the trimmed composite material before the scrap has a chance to heat weld itself back to the trimmed composite material. It is understood that in the context of this disclosure, cutting and trimming the composite material is synonymous and the terms cut and trim may be used interchangeably.
As depicted, robotic arm 106 is on rails 108. Rails 108 allow movement about the manufacturing environment. Section 114 with trimming and scrap removal system 110 and a portion of uncured composite structure 102 is shown in greater detail in
Turning now to
Uncured composite structure 204, after being cured, is a structure configured for use in platform 206. Platform 206 may be, for example, without limitation, a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, or a space-based structure. More specifically, platform 206 may be an aircraft, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, and other suitable platforms.
Platform 206 takes the form of aircraft 208 in this illustrative example. When uncured composite structure 204 is manufactured for aircraft 208, uncured composite structure 204 may be, for example, without limitation, a stringer, a spar, a rib, a panel, a stabilizer, a skin panel, or some other suitable structure configured for use in aircraft 208.
As depicted, composite manufacturing system 202 comprises trimming and scrap removal system 210, robotic arm 212, tool 214, movement system 216, controller 218, and vision system 220. Trimming and scrap removal system 210 takes the form of an end effector for robotic arm 212 such that trimming and scrap removal system 210 is connected to robotic arm 212. Trimming and scrap removal system 210 may be removably connected to robotic arm 212 such that if robotic arm 212 is needed to perform other processes, trimming and scrap removal system 210 may be removed and another end effector can be attached to robotic arm 212. Robotic arm 212 moves trimming and scrap removal system 210 about number of axes 228 as desired relative to uncured composite structure 204. As used herein, “a number of” when used with reference to items means one or more items. Thus, a number of axes is one or more axes.
As illustrated, tool 214 is configured to support and hold uncured composite structure 204 in place during processing. Tool 214 may include one or more support structures such as a clamp, a bladder, a ballast, a block or some other suitable structure for holding uncured composite structure 204 in place during processing.
In this illustrative example, trimming and scrap removal system 210 includes knife 222, parting horn 224, and web support 226.
When cutting/trimming uncured composite structure 204 with trimming and scrap removal system 210, knife 222 cuts uncured composite structure 204 along path 232. As knife 222 cuts or trims uncured composite structure 204 along path 232, scrap 234 is trimmed from trimmed part 236. Parting horn 224 separates scrap 234 from trimmed part 236 so that the scrap does not become heat welded back to trimmed part 236. Web support 226 provides a firm, planar surface that supports the portion of uncured composite structure 204 being trimmed. In other words, web support 226 acts a cutting board for knife 222.
Knife 222 takes the form of an ultrasonic 230 knife in this illustrative example. The position of knife 222 relative to robotic arm 212 is adjustable 240. Knife 222, being ultrasonic 230, includes a corresponding vibration generator 242. Knife 222 has trim angle 244. Trim angle 244 is important to the success of the cut. An optimal trim angle 244 ranges from 20°-60° relative to the uncured composite structure. Based on signals received from vision system 220 and controller 218, trim angle 244 may be adjusted to provide a desired shape of cut for uncured composite structure 204. In an example, trim angle 244 may be adjusted dynamically in response to changes in dimension or curvature in uncured composite structure 204 as trimming and scrap removal system 210 moves along path 232. A typical ultrasonic knife blade is generally triangular in shape. As a result, knife 222 includes trailing edge 246. Trailing edge 246 will be used to position parting horn 224 relative to knife 222. In this illustrative example, path 232 is normally a predetermined and programmed trim path but can also be dynamically adjusted during use. Knife 222 follows path 232 along the entire length 238 of uncured composite structure 204.
Parting horn 224 takes the form of an ultrasonic 248 parting horn in this illustrative example. The position of parting horn 224 relative to knife 222 is adjustable 250. As is the position of knife 222, the position of parting horn 224 relative to robotic arm 212 is also adjustable 240. Parting horn 224, being ultrasonic 248, includes a corresponding vibration generator 252. Vibration generator 252 is separate from vibration generator 242 for knife 222. It may be necessary for knife 222 and parting horn 224 to vibrate at different frequencies to affect a desired cut/trim and scrap removal. Parting horn 224 is generally wedge shaped and includes leading edge 254. Parting horn 224 is positioned relative to knife 222 such that leading edge 254 of parting horn 224 is generally parallel with trailing edge 246 of knife 222. The distance between knife 222 and parting horn 224 depends on several factors such as the uncured composite structure 204 to be trimmed and the rate at which trimming and scrap removal system 210 moves along path 232. It is important that the distance between knife 222 and parting horn 224 is enough such that they do not touch. Damage to knife 222 or parting horn 224 or both would mostly likely should the two ultrasonic components were to touch during operation.
Parting horn 224 is generally wedge shaped and includes surface 256 which contacts scrap 234. From the wedge shape of parting horn 224, surface 256 is at angle 258 relative to path 232. Angle 258 is generally at a 1 to 5 rise-over-run ratio. Further, parting horn 224 is spaced from trimmed part 236 such that parting horn 224 imparts zero forces on trimmed part 236. As illustrated, surface 256 may include dimples 260.
The position of web support 226 relative to knife 222 is adjustable 262. The position of web support 226 relative to parting horn 224 is adjustable 262. As is the position of knife 222 and the position of parting horn 224, the position of web support 226 relative to robotic arm 212 is also adjustable 262. Web support 226 includes backing 264. Backing 264 is generally planar. Backing 264 can be static 268 or moving 270.
Static 268 backing 264 is understood to mean that as knife 222 and parting horn 224 and web support 226 move as a system along path 232, uncured composite structure 204 slides across a backing 264 of web support 226. In other words, as trimming and scrap removal system 210 moves along path 232, the components of trimming and scrap removal system 210 including knife 222, parting horn 224, and web support 226 move together relative to uncured composite structure 204. Backing 264 of static 268 web support 226 that supports uncured composite structure 204 as uncured composite structure 204 is being trimmed is porous 272. The porous nature of web support 226 when static 268 releases positive air pressure as uncured composite structure 204 is cut and creates an air gap to reduce friction between uncured composite structure 204 and web support 226.
A reduced friction surface between uncured composite structure 204 and web support 226 provided by porous 272 static 268 backing 264 helps to prevent trimmed part 236 from inadvertently sticking to web support 226 as trimming and scrap removal system 210 moves along path 232. A reduced friction surface between uncured composite structure 204 and web support 226 helps prevent or at least minimizes stresses, strains, wrinkling, or any other defect that may occur in trimmed part 236 should trimmed part stick to web support 226.
Moving 270 backing 264 includes conveyor belt track 274. Conveyor belt track 274 is a continuous tread riding on guide wheels 276. Conveyor belt track 274 and guide wheels 276 operate in a similar manner to a treadmill or tank tread. As trimming and scrap removal system 210 moves along uncured composite structure 204 on path 232, conveyor belt track 274 rolls on uncured composite structure 204. Guide wheels 276 are dynamically steerable 278 in order adjust the position of conveyor belt track 274 in order to accommodate varying web heights of uncured composite structure 204 and curvature along the length of uncured composite structure 204.
Controller 218 is a device that controls the behavior of the components within trimming and scrap removal system 210. Based on information from vision system 220 and other systems, controller 218 adjusts parameters for trimming and scrap removal system 210. Specifically, controller 218 is configured to adjust at least one of rate of speed knife 222 cuts uncured composite structure 204, direction, position, depth, and trim angle 244 based on information received from components in trimming and scrap removal system 210.
For example, without limitation, as the thickness of uncured composite structure 204 increases along path 232, controller 218 may slow down trimming and scrap removal system 210 to promote the integrity of the cut, reduce blade deflection, and reduce the risk of deformation of knife 222. In other cases, if the composite material is thin, trimming and scrap removal system 210 may move faster through these portions of uncured composite structure 204 to promote efficiency in processing. Adjustments in other parameters allow for trimming of uncured composite structure 204 in multiple geometries and to correct trimming and scrap removal system 210 as desired in real time.
As used herein, the phrase “at least one of,” when used with a list of items, means different combinations of one or more of the listed items may be used, and only one of each item in the list may be needed. In other words, “at least one of” means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item may be a particular object, a thing, or a category.
For example, “at least one of item A, item B, or item C” may include, without limitation, item A, item A and item B, or item B. This example also may include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be present. In other examples, “at least one of” may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.
Vision system 220 provides visual feedback for trimming and scrap removal system 210. Vision system 220 may include a camera, a video camera, laser sensors, or other suitable components. Vision system 220 provides visual feedback as trimming and scrap removal system 210 follows path 232 along uncured composite structure 204. Vision system 220 provides information to controller 218.
In this depicted example, movement system 216 is associated with robotic arm 212. Movement system 216 comprises various components configured to move robotic arm 212 along length 238 of uncured composite structure 204 to trim uncured composite structure 204. Movement system 216 may take the form of rails, wheels, or other suitable movement mechanisms. In some cases, movement system 216 and robotic arm 212 may comprise an autonomous vehicle capable of moving freely about manufacturing environment 200.
With an illustrative embodiment, composite manufacturing system 202 can work more efficiently and with more versatility to trim uncured composite structure 204 than previously contemplated. As a result, uncured composite structure 204 is formed more quickly and with less rework than with currently used systems.
The illustrative embodiments are designed to allow for trimming and scrap removal system 210 to cut uncured composite structures and separate scrap 234 from trimmed part 236 before scrap has a chance to heat weld back to trimmed part. Parting horn 224 pushes scrap 234 away from trimmed part 236 of uncured composite structure 204 while parting horn 224 exerts no force on trimmed part 236 of uncured composite structure 204. Robotic arm 212 moves trimming and scrap removal system 210 about uncured composite structure 204 such that flipping is not necessary, thus reducing manpower. All parameters of trimming and scrap removal system 210, including the positions of knife 222, parting horn 224, and web support 226 relative to each other, may be adjusted in real time, allowing trimming and scrap removal system 210 to perform more complex operations than previously used systems.
With reference next to
As depicted, trimming and scrap removal system 300 comprises knife 302, parting horn 304, and web support 306. Knife 302 may be an ultrasonic knife and parting horn 304 may be an ultrasonic parting horn. Knife 302 and parting horn 304 are each connected to separate vibration generators. Web support 306 includes backing 310 that moves around guide wheels 312. For clarity and illustration purposes, only a planar portion of backing 310 that contacts uncured composite structure 301 as trimming and scrap removal system 300 moves along uncured composite structure 301 is depicted. In actuality, backing 310 is a looped tread that moves around guide wheels 312. Trimming and scrap removal system 300 moves along path 308 in direction 316 along uncured composite structure 301.
As illustrated, knife 302 is positioned relative to uncured composite structure 301 at trim angle 314. Trim angle 314 ranges from 20°-60° relative to path 308 along the uncured composite structure.
Turning now to
Knife 402 is positioned relative to path 404 at trim angle 406. The components of the trimming and scrap removal system move along path 404 in direction 410 to trim an uncured composite structure. Trailing edge 408 of knife 402 is generally parallel with leading edge 414 of parting horn 416. Parting horn 416 is spaced 418 from knife 402.
Parting horn 416 is generally wedge shaped and includes surface 420 which contacts the scrap trimmed from the uncured composite structure. From the wedge shape of parting horn 416, surface 420 is at angle 422 relative to path 404. Angle 422 is generally at a 1 to 5 rise-over-run ratio. Further, parting horn 416 is spaced distance 424 from path 404 or the trimmed part such that parting horn 224 imparts zero forces on the resulting trimmed part.
Turning now to
As depicted parting horn 602 is generally wedge shaped from the side and is symmetrical from the top. Parting horn 602 includes leading edge 604 and surface 606. Leading edge 604 is intentionally dull so that it does not inadvertently begin a second cutting path in the uncured composite structure. Surface 606 pushes scrap away from a trimmed part of the uncured composite structure while parting horn 602 exerts no force on the resultant trimmed part. Surface 606 is at angle 608 relative to path 610. Angle 608 is generally at a 1 to 5 rise-over-run ratio.
Turning now to
As depicted parting horn 802 is generally wedge shaped from the side and is asymmetrical from the top. Parting horn 802 includes leading edge 804 and surface 806. Surface pushes scrap away from a trimmed part of the uncured composite structure while parting horn 802 exerts no force on the resultant trimmed part. Surface 806 includes dimples 808. Dimples 808 reduce contact surface area with the scrap and thus reduce friction on surface 806 to allow scrap to slide off parting horn 802.
With reference next to
Knife 1002 cuts through uncured composite structure 1004 along path 1006. Parting horn 1008 pushes scrap 1010 away from trimmed part 1012 as knife 1002 and parting horn 1008 move along path 1006 in direction 1014.
Turning now to
For clarity and ease of illustration, web support 226 is depicted without a backing in order to show the relative movements of guide wheels 1104 and 1106. In this illustrative embodiment, backing (not shown) is a moving backing and is in the form of a conveyor belt track looped around guide wheels 1104 and 1106.
A position of guide wheel 1106 is adjustable with respect to guide wheel 1104. Rotation of ball screw 1110 forces collar 1112 to translate in direction 1116 along the length of ball screw 1110. Ball screw 1110 may rotate in either direction thus converting lateral movement of collar 1112 in either direction 1116. As collar 1112 translates in direction 1116, link 1114 connected to guide wheel 1106 forces guide wheel 1106 to pivot about pivot point 1118. The position of guide wheel 1106 is dynamically adjustable in order adjust the position of the conveyor belt track of the backing (not shown) to accommodate varying web heights and curvature along the length of the uncured composite structure to be trimmed. As guide wheel 1106 moves, both guide wheels work in conjunction to position the backing (not shown) of the web support such that the backing always provides a firm planar support surface supporting the uncured composite material as the knife cuts the uncured composite material.
With reference next to
Knife 1302 is positioned relative to parting horn 1304. Web support 1306 supports the web of uncured composite structure 1308 as trimming and scrap removal system 1300 moves along path 1310 in direction 1312. Web support 1306 includes backing 1320. Backing 1320 is static. Backing 1320 is porous. As trimming and scrap removal system 1300 moves along path 1310 in direction 1312, uncured composite structure 1308 and the resultant trimmed part slide against backing 1320. The porous nature of backing 1320 releases positive air pressure as uncured composite structure 1308 is cut and creates an air gap to reduce friction between uncured composite structure 1308 and web support 1306.
The different components shown in
Other configurations for composite manufacturing system 100 may be implemented other than those shown in
Although the illustrative embodiments are shown and described with reference to forming stringers for aircraft applications, the illustrative embodiments can be used with any type of platform to trim and remove scrap from composite parts for that platform.
With reference next to
The process begins by positioning an ultrasonic knife relative to an uncured composite structure (operation 1402). The ultrasonic knife is connected to a robotic arm. The ultrasonic knife is positioned at a trim angle relative to the path of a trimming and scrap removal system. Next, an a parting horn is positioned relative to the ultrasonic knife and spaced from the uncured composite structure (operation 1404). The parting horn is connected to a robotic arm. the uncured composite structure is trimmed with the ultrasonic knife along the path (operation 1406).
Thereafter, the parting horn separates scrap from the uncured composite structure along the path (operation 1408). At operation 1410, the uncured composite structure is supported with a web support. If needed, the position of a backing of the web support is dynamically adjusted (operation 1412). Scrap is pushed away from the uncured composite structure with the parting horn while the parting horn exerts no force on the uncured composite structure (operation 1414).
Illustrative embodiments of the disclosure may be described in the context of aircraft manufacturing and service method 1500 as shown in
During production, component and subassembly manufacturing 1506 and system integration 1508 of aircraft 1600 in
Uncured composite structure 204 from
Each of the processes of aircraft manufacturing and service method 1500 may be performed or carried out by a system integrator, a third party, an operator, or some combination thereof. In these examples, the operator may be a customer. For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military entity, a service organization, and so on.
With reference now to
Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method 1500 in
With the use of an illustrative embodiment, a composite manufacturing system can work more efficiently with less risk of heat welding scrap material back to a trimmed part. The ultrasonic parting horn of the disclosed trimming and scrap removal system is configured to separate scrap from the uncured composite structure so that the scrap does not stick to the trimmed part. Composite structures may be trimmed prior to or after curing and multiple robots may move about the manufacturing environment to trim the composite structure at the same time.
In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added, in addition to the illustrated blocks, in a flowchart or block diagram.
The description of the different illustrative embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different illustrative embodiments may provide different features as compared to other desirable embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.
