• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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    • 专利摘要:
    METHOD AND APPARATUS FOR MANUFACTURING REINFORCEMENT OF COMPOSITES CONTROLLED WITH VARIABLE BITOLA. The present invention relates to a tool apparatus for forming a composite load on a stringer composed of the contour paddle that includes an elongated perforator and a flexible die along its lengths. The load is formed by a press using the perforator to drive the load to the die. The punch and die are mounted between a pair of flexible plates. A press coupled with the plates outlines the load by bending the plates into a desired contour.
    公开号:BR102012021009B1
    申请号:R102012021009-6
    申请日:2012-08-22
    公开日:2020-12-08
    发明作者:Daniel M. Rotter；Michael R. Chapman；Brad A. Coxon；Paul E. Nelson
    申请人:The Boeing Company；
    IPC主号:
    专利说明:

    BACKGROUND INFORMATION FIELD
    [0001] The present invention in general relates to the manufacture of composite structures, and deals more particularly with a method and an apparatus for the formation of flat composite loads in contoured reinforcement substructures, such as variable gauge blade reinforcers . BACKGROUND
    [0002] Composite reinforcement substructures, such as blade reinforcers, sometimes referred to as blade stringers, are often used for the maritime and aircraft industries. These stringers can be manufactured by combining two or more reinforcement members. For example, blade-type stringers can be manufactured by combining two members having L or C cross-sectional shapes in opposition. These members can be formed manually by a hot curtain forming several composite loads along a mandrel or other tool. After forming, the members are placed back to back and co-treated in an autoclave. The manufacture of multi-load blade stringers that requires multiple tools is relatively labor intensive and can add flow times to the manufacture.
    [0003] In some applications, reinforcers such as the blade rails mentioned above, may have to be contoured along their lengths, in order to conform them to a structure such as a contoured aircraft liner, to which they are attached. to be attached. Difficulty can be encountered, however, when trying to form highly contoured stringers using conventional tools, due to the tendency of the tarpaulins in the cargo to wrinkle as the cargo is being compressed. Thus, the manufacture of highly contoured liners using composites is generally limited to manual laying techniques in which each layer is deposited by hand along a die or other tool, in order to reduce the possibility of layer wrinkling. The manual laying technique is labor-intensive, and thus expensive, as well as relatively slow. An additional challenge is presented, where one or more areas of the stringer include deep falls and / or sudden elevations of the layer, in order to conform the stringer to the local skin contour.
    [0004] Therefore, there is a need for a method and apparatus for the manufacture of composite reinforcers, such as blade stringers using a single composite load formed with relatively simple tools. There is also a need for a method and apparatus of the aforementioned type that allows the contour of the stringer along its length, including the localized contour using deep falls or sudden elevations of the layer. SUMMARY
    [0005] The described modalities provide a method and an apparatus for the manufacture of blade-type stringers using simplified tools to form a single composite load in a desired stringer configuration. Tool costs and process flow times can be reduced, eliminating the need to form multiple loads and assemble multiple reinforcement members in order to achieve the desired stringer configuration. The modalities allow localized contours of the stringer, accommodating deep falls and sudden elevations of the layer along the length of the stringer. The load can be bypassed along its length during formation with reduced layer wrinkling and / or reduced layer misalignment.
    [0006] According to a described modality, the device is provided for the formation of a compound load bypassed with the blade stringer. The apparatus comprises a flexible elongated perforator along its length and a flexible elongated die along its length in which a generally flat composite load can be formed by pressing through the perforator. The apparatus also includes the first and second flexible plates respectively supporting the first and second layers, and a press coupled with the blades to form the perforator and the die in a desired contour.
    [0007] According to another described modality, the apparatus is provided for the formation of a composite load in a contoured blade reinforcer having a flange with at least a variation in thickness. The apparatus includes a flexible first and second plates, and an elongated perforator and an elongated die. A generally flat composite load can be formed by pressure between the punch and the die. The perforator and the die are flexible along their respective lengths and are placed between the first and second plates. The apparatus includes at least one first wedge located between one of the plates and the die to maintain substantially constant pressure on the load throughout the thickness variation during pressure forming. The apparatus further comprises a press for folding the plates to circumvent the parts and the die. The wedge is generally flexible.
    [0008] According to an additional embodiment, a method of making a composite reinforcement blade is provided. The method comprises the formation of a generally flat hat-shaped load having a pair of flanges using the perforator to dry its load in a cavity in a die. A plate is loaded through the die covering the flanges, and the punch is forced against the plate to compress and maintain the flanges. The shape of the hat is formed within a blade of the reinforcer, compressing the die while the plate is pressed against the flanges by the perforator.
    [0009] According to yet another modality, a method of manufacturing a reinforcer composed of the contoured blade is provided. The method comprises placing a substantially flat composite load on a die and forming the flat load inside a hat using a perforator to press the form against the load in a cavity in the die. The method also comprises the contour. The load is formed by flexing the die while the load is formed on the die. Bypassing the formed load includes bending the punch while the punch is in the die.
    [00010] In summary, according to one aspect of the invention, an apparatus is provided for forming a compound load on a contoured blade longitudinal, including a flexible elongated perforator along its length; an elongated flexible die along its length on which a generally flat composite load can be formed by pressure through the perforator; first and second flexible plates respectively supporting the first and second dies, and a mechanism for changing the contour of the die and the punch coupled with the plates to change the outline of the punch and die.
    [00011] Advantageously, the apparatus in which the perforator is generally flat and includes a plurality of individual segments of the perforator.
    [00012] Advantageously, the apparatus in which the die includes first and second spaced die portions which define a die cavity between which the perforator can be received.
    [00013] Advantageously, the apparatus in which the stamp portions are laterally movable in relation to each other to compress the load between them, and the apparatus further comprises: expandable members to apply a lateral force on the stamp portions which compress the charge.
    [00014] Advantageously, the apparatus in which the expandable members include a pair of inflatable hoses, respectively on opposite sides of the die portions and adapted to be coupled with a source of pressurized air.
    [00015] Advantageously the device still includes at least one block adapted to engage the load and having a contour generally a contour corresponding to the location in the load.
    [00016] Advantageously, the apparatus also includes a press coupled with the first and second plates for the contour of the plates while the load is between the punch and the die.
    [00017] Advantageously, the apparatus also includes a removable installation plate between the die and the punch to maintain a portion of the load during the formation of the load.
    [00018] According to another aspect of the invention there is provided an apparatus for forming a composite load in a contoured blade reinforcer having a flange with at least a variation in thickness, including the first and second flexible plates; an elongated perforator and an elongated die, among which a generally flat composite load can be formed by pressure, the perforator and the die being flexible along their respective lengths and placed between the first and second plates, and at least one first chock located between one of the plates and the die, and a press to bend the plates to bypass the punch and the die.
    [00019] Advantageously, the device in which the wedge is generally flexible.
    [00020] Advantageously, the apparatus also includes a second shim, and the first shim is located between a first side of the die and the first plate, and the second shim is located between a second side of the die and the second plate .
    [00021] Advantageously, the apparatus in which the perforator is generally flat and includes a plurality of individual segments of the perforator, and the die includes a flexible first and second separate spaced portions that define a cavity of the die between which the perforator can be. Received.
    [00022] Advantageously the apparatus also includes a pair of inflatable hoses, respectively on opposite sides of the die portions and adapted to be coupled with a source of pressurized air for the application of a lateral force on the die portions.
    [00023] Advantageously, the device in which the first shim includes a cone generally corresponding to the variation in thickness.
    [00024] In accordance with a further aspect of the present invention, there is provided a method of manufacturing a reinforcer composed of the blade, including forming a generally flat charge; using a perforator to form the load in the form of a hat having a pair of flanges, carrying the generally flat load into a cavity of a die; remove the perforator from the die cavity; load a plate on the die covering the flanges; keep the flange portions against the die, forcing the punch against the plate; and forming the shape of the resulting hat on a blade using the die to compress the hat while the flange portions are held against the die.
    [00025] Advantageously, the method also includes additionally placing the load on the die.
    [00026] Advantageously, the method also includes placing a heating mat over the load on the die, and heating the load to a formation temperature using the heating mat.
    [00027] Advantageously, the method further includes the contour of the load along its length through the contour of the die and the perforator before the blade is formed.
    [00028] Advantageously, the method also includes the contour of the load along its length through the contour of the die and the perforator after the blade is formed.
    [00029] Advantageously, the method further includes placing a filler material between the flange portions after the blade has been formed; reload the plate over the flange portions and the filling material, and compress the filler, driving the punch down against the plate.
    [00030] In accordance with another aspect of the present invention, there is provided a method of manufacturing a reinforced compound of the contoured blade, including placing a substantially flat composite load on a die having a die cavity; pressure forming the flat load against the die, including the use of a perforator to pressure press the load into a hatform inside the die cavity; and bypassing the load formed by bending the die while the load is formed on the die.
    [00031] Advantageously, the apparatus in which the pressure formation includes forming flange portions of the load against the die while the perforator is formed into a hat-shaped load inside the die cavity, removing the perforator from the die cavity , and using the stamp to compress the hat laterally on a blade.
    [00032] Advantageously, the device in which the contour is performed before the hat is compressed on a blade.
    [00033] Advantageously, the apparatus in which the contour of the formed load includes bending the perforator, together with the die.
    [00034] In accordance with another aspect of the present invention, an apparatus is provided for forming a contoured contoured blade member with variable gauge, including spaced, elongated, flexible first and second separate plates; a die mounted on the first plate facing the second plate, the die including the first and second die portions having a die cavity between them, each of the die portion being segmented into a plurality of independently movable die blocks sliding on the first plate, the additional die, including flexible strips of engagement of the die blocks together; a pair of supports fixed to the first plate on opposite sides of the section to laterally retain the die blocks; a pair of hoses, respectively, between the die blocks and the supports adapted to be coupled with a source of pressurized air to apply a lateral force on the die portions; a first tapered wedge between each of the stamp portions and the first plate for transmitting constant force to the areas of the load having variations in thickness as the load is being formed; a substantially flat, elongated perforator mounted on the perforator and extending substantially perpendicular to the second plate to form a portion of the load within the die cavity, the perforator being segmented into a plurality of movable portions of the perforator independently; a second tapered shim on each side of the perforator and attached to the second plate for constant force transmission to the areas of the load having variations in thickness as the load is being formed, and a plurality of actuators, together with the first and second plates to form the perforator and the die in a desired contour by flexing the plates.
    [00035] In accordance with yet another aspect of the present invention, another method of forming a stringer composed of the contoured blade with variable gauge is provided, including providing a substantially flat pre-impregnated multiple composite load; put a first filler on the load; placing the load flat on a die having two opposite portions of the die and a die cavity between them; heat the load to a formation temperature; use a perforator to drive a first portion of the load and the first filler into the groove of the die to form a hat; use a first plate to compress the second portion of the load against the die to form flange portions of the string as the hat is being formed by the perforator; retract the perforator from the die cavity; load a second plate over the stringer flange portions; hold the flange portions against the die using the perforator to apply pressure to the second plate; remove the second plate; use a pair of pressurized hoses to apply lateral pressure, respectively to the portions of the die; use the portions of the stamp to form the hat on a blade, compressing the hat between the portions of the stamp; contour the load formed by each perforator contour and the die along their respective lengths while the blade is being compressed; placing a second composite filler in a groove between the flange portions; apply an adhesive and a layer of fabric over the second filler; reloading the second plate over the flange portions, which cover the second filler, the adhesive and the fabric layer; use the perforator to apply pressure to the second plate and compress the second filler, the adhesive and the fabric layer; retract the perforator after the second filling material has been compressed; move the portions away from each other; remove the second plate, and remove the stringer formed from the die. BRIEF DESCRIPTION OF THE DRAWINGS
    [00036] The new accredited characteristics of the advantageous modalities are defined in the attached claims. Advantageous embodiments, however, as well as a preferred mode of use, other objectives and advantages thereof, will be better understood by reference to the following detailed description of an advantageous embodiment of the present invention, when read in conjunction with the accompanying drawings, in which :
    [00037] Figure 1 is an illustration of a side view of a stringer composed of the contoured blade manufactured with the method and apparatus described.
    [00038] Figure 2 is an illustration of a sectional view taken along line 2-2 in figure 1.
    [00039] Figure 3 is an illustration similar to figure 2, but showing an alternative shape of the stringer.
    [00040] Figure 4 is an illustration of a perspective view of the tool apparatus used to form a substantially flat load for the blade side members shown in figures 1 to 3.
    [00041] Figure 5 is an illustration of a sectional view taken along line 5-5 in figure 6, but showing a load to be formed.
    [00042] Figure 6 is an illustration of a sectional view taken along line 6-6 in figure 5.
    [00043] Figure 6A is a plan view of a portion of a blade with an elevation, showing how the die blocks move to conform to the contours of the blade during the forming process.
    [00044] Figure 7 is an illustration of a plan view of a mechanism for changing the contour of the die and the perforator using the tool set shown in Figure 4.
    [00045] Figure 8 is an illustration of a flow diagram of a method of manufacturing the contoured blade stringer shown in figures 1 and 2.
    [00046] Figures 9 to 25 are schematic illustrations of a tool apparatus shown in figure 4, respectively showing the sequential steps of the manufacturing method shown in figure 8.
    [00047] Figure 26 is an illustration of a flow diagram of a method of manufacturing the contoured blade stringer shown in figure 3.
    [00048] Figures 27 to 43 are schematic illustrations of a tool apparatus shown in figure 4, respectively showing the sequential steps of the manufacturing method shown in figure 26.
    [00049] Figure 44 is an illustration of an aircraft production flow diagram and service methodology.
    [00050] Figure 45 is an illustration of a block diagram of an aircraft. DETAILED DESCRIPTION
    [00051] Referring first to figures 1 and 2, the embodiments described refer to a method and apparatus for manufacturing an elongated, composite composite reinforcer, such as a blade-type stringer 50 having a substantially flat blade 52 and a flange 54 that extend substantially perpendicular to the blade 52. The flange 54 includes a pair of flange portions 54a that extend laterally from one end of the blade 52, and connected to the blade 52 by a section of radius 60. The stringer of the blade 50 may have one or more contours 58 along its length. In the illustrated embodiment, the stringer 50 has a substantially constant contour 58 in the curved plane 56 of a flange 54. In other embodiments, the stringer 50 may have one or more of the contours 58, which may or may not be in constant curvature. In addition, as will be discussed in more detail later, the flange 54 can have a variable gauge, or thickness T1 in one or more locations along its length, in order to conform the stringer 54 to the localized contours of a structure to which it is attached, like an aircraft liner 61. In addition, the thickness T2 and / or a height H of the blade 52 may vary over the length of the stringer 50.
    [00052] The method and apparatus described can be used to manufacture other configurations of blade-type stringers 50, such a hybrid I-stringer 50a shown in figure 3. The stringer 50a comprises a blade 52 having an angled end 62 , and a flange 54. The end of the blade 62 includes a triangularly formed composite filler 64, however other forms of fillers are possible. The flange 54 includes a V-shaped groove 57 at the intersection of the flange portions 54a with the blade 52. The groove 57 is filled with a composite filler 66 having a triangular cross section substantially corresponding to the groove 57. Each of the grooves grinders 64, 66 may comprise an adhesive that may or may not be fiber reinforced, or alternatively may comprise strips (not shown) of pre-impregnated tape.
    [00053] Figures 4 to 6 illustrate the tool apparatus 68, which can be used to form the stringers shown in figures 1 to 3 using a single, substantially flat, multilayer composite load 55. The load can comprise multiple layers 59 of composite material, such as, without limitation, a pre-impregnated epoxy carbon fiber, and may include elevations 98 to conform to the flange 54 (figure 2) of the stringer 50 to local contours, such as local skin contours 61. The The tool apparatus 68 broadly comprises a lower die 70, an upper punch 88 and a pair of flexible plates 72, 74, on which the die 70 and the punch 88 are respectively mounted. The die 70 comprises a pair of die portions 70a, 70b which are spaced apart to form a die cavity 86 and are sliding, substantially laterally, towards and away from each other in the plate 72. Each of the portions of die 70a, 70b is segmented at 75 and comprises a plurality of die blocks 76 which, in the illustrated example, have a generally rectangular cross-section, however other cross-sectional shapes are possible.
    [00054] The die blocks 76 are aligned side by side along the length of the plates 72, 74 and are joined by means of flexible connectors 78 which can comprise, for example, and without limitation, a flexible metal strip. The die blocks 76 are mounted on the plate 72 and are interconnected by means of connectors 78 in such a way that their respective axes maintain neutrality during molding and the contour of the load 55. The die blocks 76 can comprise any material, suitable relatively rigid, such as wood, metal, ceramic or a composite, and include interior forming surfaces 76a and upper forming surfaces 76b. A pair of elongated L-shaped supports 82 is mounted on the plate 72, on opposite sides of the die 70, and operated for both to retain the die blocks 76 on the plates 72, as well as to react to the lateral forming forces generated by the die blocks. 76. A pair of inflatable hoses 84, sometimes referred to as bags or bladders, are placed between the supports 82 and the die blocks 76, which are adapted to be coupled with a suitable source of compressed air (not shown). The hoses 84 can be selectively pressurized in order to apply a lateral force on the die blocks 76 during forming and / or bypass operations. Other mechanisms, however, can be provided to apply lateral force to the die blocks 76.
    [00055] The perforator 88 is substantially flat and includes slits 90 that segment the perforator 88 into a plurality of portions of the perforator 92 that allow the perforator 88 to flex along its length in a plane (not shown) that is substantially perpendicular to the plane 56 (figures 1 and 2) of the flange 54. The perforator 88 can be formed of any suitable rigid material, such as metal, ceramic or a composite.
    [00056] As mentioned earlier, the stringer 50 can have a variable flange thickness T1 in areas located along its length, in order to conform the stringer 50 to the local contours of the skin 61 (figure 1). In order to accommodate these thickness variations so that constant pressure is applied to the load 55 in these localized areas, the appropriate contoured upper and lower shims 80, 94, respectively, can be provided. For example, as shown in figures 4 and 6, the load 55 may include elevation layers 98 in the area of the flange portions 54a (figure 2). In order to ensure that substantially the same forming pressure is applied to the area of the elevation layers 98, the upper shims 94 include a contour 96 that is substantially in conformity with the cross-sectional shape of the elevation pads 98. Although not shown in the Figures, the lower shims 80 may also contain one or more contours along their lengths below the die blocks 76, in order to accommodate thickness variations in the flange portions 54a of the stringer 50. In addition, the lower shim 80 may be conical (not shown), in the area below the molding cavity 86 (figure 4), in order to change the height of the blade along its length. The shims 80, 94 can be formed of any substantially non-compressible material that will transmit the force to the load 55, still flexible to the degree necessary to allow the shims 80, 94 to bend during the contour of the tool apparatus 68 .
    [00057] Referring to figure 6A, as mentioned earlier, the T2 thickness of the stringer of the blade 52 may vary along its length. For example, blade 52 may have locations at elevations 97 that increase the thickness of blade T2. During the forming process, the die blocks 76 in the area 99 of the elevation 97 slide 101 laterally outward on the lower plate 72, in order to conform to the contour shown by the elevation 97, and to maintain the formation pressure substantially constant. on blade 52.
    [00058] Figure 7 illustrates a mechanism for changing the contour of the punch and punch 105 incorporating the tool apparatus 68 shown in figures 4 to 6. The mechanism for changing the contour of the punch and punch 105 can comprise, for example, and without limitation, a press 105. A plurality of separate spaced individual drivers 100 is mounted, respectively, on the opposite pressing plates 104 which are adapted for movement towards and away from each other, as shown by the arrows 106. The tools 68 is disposed between the pressing plates 104. The pressing plates 104 can be coupled with the appropriate feeding mechanisms operated such as cylinder actuators (not shown) to move the pressing plates 104, which open and close the pressing apparatus. tools 68, during a training load operation. Each of the actuators 100 includes a plunger 102 coupled with one of the plates 72, 74 which applies a force to the plates 72, 74 in order to bend the plates 72, 74, which in turn longitudinally contours the tool apparatus 68, and thus the load formed 55. Other mechanisms can be employed to longitudinally bypass the tool apparatus 68, such as that described in US Patent Publication 20100102482 published on April 29, 2010, the complete description of which is incorporated herein by reference.
    [00059] Attention is now directed to figure 8, which describes the individual steps of a method of manufacturing contoured blade stringers; these steps are also shown sequentially, in diagram form, in figures 9 to 25. Starting at step 110, a substantially flat composite multilayer load 55 is loaded 146 onto the die blocks 76 (figure 9), with the punch 88 in a raised position. A portion of the central blade 52 of the load 55 overlaps the cavity of the die 86, and the outer flange portions 54a of the load 55 extend laterally beyond the die blocks 76. The adhesive strips 148 can be placed over the load 55, before or after the load 55 is loaded onto the die blocks 76. Then, as shown in 112 in figure 8, a heating mat 150 (figure 10) is loaded 152 for load 55. Then, in 114, the charge is heated (figure 11) using the heating mat 150, thereby softening the charge 55 to a suitable formation temperature. Other types of heating devices can be used to heat the load 55, including, but not limited to, radiant and inductive type heaters (not shown). In step 116, the heating mantle 150 is discharged 154, as shown in figure 12. In step 118, a portion of the blade 52 of the load 55 is formed inside a hat 156 (figure 13), forcing the punch 88 into the hollow of die 86. As hat 156 is being formed as shown in figure 13, a first intermediate level of pressure P1 is applied to die blocks 76 by hoses 82 in order to keep die blocks 76 loaded against the load 55. However, this intermediate pressure level P1 is less than the laterally outward pressure developed by the perforator 88, consequently, although loaded against the hat 156, the die blocks 76 move laterally outward 168 until the hat section 156 is completely formed within cavity 86.
    [00060] Then, in step 120, while the pressure P1 laterally inward is maintained against the cap 156 by the dummy blocks 76 (figure 14), the top plate 74 applies pressure 164 to the flange portions 54a, the latter forming downwardly against the die blocks 76. Optionally, in step 122, the partially formed load 55 is contoured (figure 15) by the contour 85 of the tool apparatus 68, while the pressure P1 laterally inward continues to be maintained over the hat 156 by the die blocks 76. The contour 85 of the tool apparatus 68 can be made by the press shown in figure 7 previously described, which tilts the plates 72, 74 in a plane (not shown) that is substantially parallel to the plane 56 flange 54 (see figures 1 and 2). As the plates 72, 74 are bent to a desired curvature, both the perforator 88 and the die 78 flex and conform to the curvature of the plates 72, 74. As previously described in connection with figures 4 to 6, the wedges upper and lower 80, 94 keep the forming pressure substantially constant on the flange portions 54a as the tool apparatus 68 is being contoured 85 to the desired shape.
    [00061] In step 124 in figure 8, the perforator 88 is retracted from the die cavity 86 (figure 16). Then, in step 126, a substantially flat plate 160 (Fig. 17) is loaded 162 onto the flange portions 54a. In step 128, the perforator 88 is lowered 158 (figure 18) to contact the plate 160, thus, loading the plate 160 against the flange portions 54a, immobilizing the flange portions 54a. Then, in step 130, while portions of flanges 54a are held in place against the die blocks 76 by the force applied by the plate 160 and the perforator 88, pressure P2 (figure 19) is applied to the die blocks 76 by the hoses 82 which compress the hat 156 on a blade 52. The pressure P2 is a forming pressure that is greater than the pressure P1 applied to the die blocks 76 during steps 118 to 122.
    [00062] In step 134 shown in figure 8, perforator 88 is retracted 180 (figure 20), and plate 160 is removed 167 leaving a V-shaped groove 165 between flange portions 54a. In step 136 shown in figure 8, a composite filler 66 is placed in slot 165, as shown in figure 21. Then, in step 138, an adhesive strip 174 (figure 22) and a layer of fabric 172 are placed over the filler 66. In step 140, plate 160 is reloaded, overlapping flange 54 (figure 23). Then, as shown in step 142, fabric layer 172, adhesive strip 174 and pad 66 are compressed by moving the punch downward, as shown in figure 24 in contact with plate 160. Finally, in step 144 , and is shown in figure 25, the perforator 88 is retracted 180, the plate 160 is removed 184, allowing the side member of the fully formed blade 50 to be removed from the tool apparatus 68.
    [00063] It should be noted here that, in the mode of the method described, the contour of the tool apparatus 68 is executed when the load 55 is in a partially formed state as shown in figure 15. Alternatively, however, the load 55 can be bypassed, in step 132, after the hat 156 has been pressed to the blade 52 shown in figure 19. The contour of the tool apparatus 68 is optional and is not necessary when using the tool apparatus 68 to form stringers substantially straight (not shown). When the contour of the stringer is not necessary, it is not necessary to perform steps 122 to 132. In any case, the method described can advantageously allow the layer to slip during the forming and / or contouring processes that can reduce the wrinkling layer and result in finished parts that have superior characteristics and / or exhibit improved performance. In addition, in another embodiment, the contour of the load 55 along its length is made after the blade portion 52 is formed, but before the formation of the flange portions 54a on the dummy blocks 76. The filler 66 is placed in the groove 165 after the flange portions 54a have been formed in the contoured blade portion 52. This latter modality of the mentioned method can facilitate the contouring process, particularly where the more highly contoured struts 50 are to be manufactured, resulting in a quality improved part with less wrinkles and / or easier to contour the load 55.
    [00064] Attention is now directed to figure 26, together with related figures 27 to 43, which illustrate steps in a method of manufacturing a hybrid type of blade 50a stringer, as shown in figure 3. As can be seen seen from figures 27 to 43, the tool apparatus 68 uses to manufacture the length 50a shown in figure 3 is substantially similar to that previously described, with two exceptions. Specifically, as shown in Figure 27, the end of the perforator 88 includes a generally V-shaped groove 88a along the length of perforator 88 that substantially matches the size and shape of a triangular filler 64. In addition, each one of the die blocks 78 includes a chamfer or chamfer 155 along a lower edge, which assists in forming the angled end 62 of the blade 52 shown in figure 3.
    [00065] Referring now to figure 26, in step 188 a substantially flat composite load 55 (figure 27) is loaded 220 onto the die blocks 76. Adhesive strips 148 can be applied to load 55, after which the upper filler 64 is placed over the central adhesive strip, 148. Then, in 190, a heating mat 150 (figure 28) is loaded 222 for load 55. In step 192 in figure 26, mat 150 is used to heat charge 55 (figure 29) at an appropriate formation temperature. In step 194 in figure 26 the blanket 150 is discharged 224, as shown in figure 30. In step 196 the perforator 88 is moved down into the cavity of the die 86 (figure 31) to form the load 55 inside a hat 156. As the perforator 88 continues to move downwardly through the cavity 86, the top plate 74 comes into contact with the flange portions 54a, and constitutes the last downward against the die blocks 76. During step 196, the lateral pressure P1 is applied to the blocks of dies 76 by the inflatable hoses 82 (see figures 4 and 5).
    [00066] In step 198, perforator 88 is retracted (figure 33) and, in step 200, a substantially flat plate 160 (figure 34) is loaded 226 to the flange portions 54a of the partially formed load 55. In step 202, the perforator 88 is placed next to the plate 66 (figure 35) which applies pressure to the flange portions 54a to hold them against the die blocks 76. In 204, the lateral pressure P2 is applied (figure 36) by the hoses 82 to the die blocks 76, causing die blocks 76 to compress hat 156 (figure 35) on a blade 52.
    [00067] Then, in step 206 and, as shown in figure 37, the perforator 88 is removed from the plate 74 and the formed stringer 52 can be optionally contoured 85 by contouring the tool apparatus 68 using a press as shown in figure 7, a force 164 is applied to the plates 72, 74 to bend the plates 72, 74 to the desired contour. During the contour 85 of the tool apparatus 68 in step 206, P2 inner lateral pressure is maintained on the die blocks 76 by the hoses 82.
    [00068] In the contour sequence of the stringer 52 in step 206, the perforator 88 is retracted 180 as shown in 208, and the plate 160 is removed 228. In step 210 in figure 26, a lower filler 66 (figure 39) is loaded into the groove 165 between the flange portions 54a. Then, as shown in step 212 in figure 26, a strip of adhesive 148 and a layer of fabric 225 is placed over the filling material 66 (see figure 30). As shown in step 214 in figure 26, plate 160 is reloaded 230 onto flange portions 54a (figure 41). At 216, the perforator 88 is moved downwards in contact with the plate 160, which compresses the layer of tissue 225 and adhesive 148 against the filler 66. During step 216, pressure P1 is maintained on the blocks of dies 76. Finally , in step 218 in figure 26, the perforator 88 is retracted 180 (figure 43), the plate 160 is removed 232 and the completed stringer 52 is removed from the tool apparatus 68.
    [00069] As mentioned earlier, the contour of the tool apparatus 68 is optional when performing the method shown in figures 26 to 43, and is not necessary when using the tool apparatus 68 to form substantially straight stringers (not shown) with the hybrid-I shape shown in figure 3. When stringer contour is not necessary, steps 198 to 206 are not necessary. In the mode described in connection with figures 27 to 43, the contour of the blade portion 52 is performed after the portions of the flanges 54a have been formed. Alternatively, however, it may be preferable in other embodiments to form the flange portions 54a, after the blade portions 52 have been formed, after which the upper filler 66 can be installed. By contouring the load 55 before the flange portions 54 have been formed, the contouring process can be easier and / or part of the quality can be improved.
    [00070] The embodiments of the invention can find use in a variety of potential applications, in particular in the transport industry, including, for example, aerospace, marine, automotive applications and other applications in which automated seated equipment can be used. Thus, referring now to figures 44 and 45, the modalities of the invention can be used in the context of aircraft construction and service method 236, as shown in figure 44 and an aircraft 238 as shown in figure 45. Applications of Aircraft of the described modalities may include, for example, without limitation, the installation of reinforcement members, such as, without limitation, spars and masts. During pre-production, exemplary method 236 may include specification and design 240 for aircraft 238 and material acquisition 242. During production, the component, manufacture of subassembly 244 and integration system 246 for aircraft 238 take place. Subsequently, aircraft 238 may undergo certification and delivery 248 in order to be placed in service 250. While in service by a customer, aircraft 238 is scheduled for routine maintenance and service 250, which may also include modification , reconfiguration, remodeling, and so on.
    [00071] Each of the 236 method processes can be performed or performed by an integrating system, a third party, and / or an operator (for example, a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and subcontractors to the main system; third parties may include, without limitation, any number of vendors, subcontractors and suppliers, and an operator may be an airline, leasing company, military entity, service organization, and so on.
    [00072] As shown in figure 45, the aircraft 238 produced by the exemplary method 236 can include a structure 254 with a plurality of systems 256 and an interior 258. Examples of high-level systems 256 include one or more of a 260 propulsion system , an electrical system 262, a hydraulic system 264, and an environmental system 266. Any number of other systems can be included. Although an aerospace example is shown, the principles of the invention can be applied to other industries, such as the marine and automotive industries.
    [00073] The systems and methods incorporated in this document can be employed in any one or more of the 236 production and service method phases. For example, the components or subassemblies corresponding to the production of process 244 can be manufactured or produced similar to the components or subassemblies produced while the 238 aircraft is in service. In addition, one or more of the device's modalities, the method's modalities, or a combination of them can be used during production phases 244 and 246, for example, by substantially speeding up assembly or reducing the cost of a 238 aircraft. likewise, one or more modal apparatus, method modalities, or a combination thereof can be used when aircraft 238 is in service, for example, and without limitation, for maintenance and service 252.
    [00074] The description of the different advantageous modalities has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the modalities in the described forms. Many modifications and variations will be evident to those skilled in the art. In addition, different advantageous modalities can provide different advantages compared to other advantageous modalities. The selected modality or modalities are chosen and described in order to better explain the principles of the modalities, the practical application, and to allow others skilled in the art to understand the invention for various modalities with various modifications that are suitable for the particular use contemplated. .
    权利要求:
    Claims (6)
    [0001]
    1. Method for making a composite blade reinforcer (50), characterized by the fact that it comprises: forming a generally flat load (55); using a perforator (88) to form the load (55) in a hat shape having a pair of flanges (54) by driving the generally flat load (55) into a cavity (86) in a die (70); removing the perforator (88) from the cavity (86) of the die (70); load a plate (160) on the die (70) covering the flanges (54); hold the flange portions (54a) against the die (70), forcing the punch (88) against the plate, and form the resulting hat shape on a blade using the die (70) to compress the hat while the flange portions (54a) are held against the stamp (70).
    [0002]
    2. Method, according to claim 1, characterized by the fact that it also comprises: placing the load (55) on the die (70).
    [0003]
    3. Method, according to claim 1 or 2, characterized by the fact that it further comprises: placing a heating blanket (150) over the load (55) on the die (70), and heating the load (55) to a temperature training using the heating mat (150).
    [0004]
    4. Method according to any one of claims 1 to 3, characterized by the fact that it further comprises: bypassing the load (55) along its length by bypassing the die (70) and the perforator (88) before the blade is formed .
    [0005]
    Method according to any one of claims 1 to 4, characterized by the fact that it further comprises: bypassing the load (55) along its length by bypassing the die (70) and the perforator (88) after the blade is formed .
    [0006]
    Method according to any one of claims 1 to 5, characterized by the fact that it further comprises: placing a filler (66) between the flange portions (54a) after the blade has been formed; reload the plate over the flange portions (54a) and the filler (66), and compress the filler (66) by driving the perforator (88) down against the plate.
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    同族专利:
    公开号 | 公开日
    ES2717191T3|2019-06-19|
    BR102012021009A2|2014-12-02|
    RU2599292C2|2016-10-10|
    EP2561979A2|2013-02-27|
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    CN102950693A|2013-03-06|
    JP6096434B2|2017-03-15|
    US20130049258A1|2013-02-28|
    RU2012136102A|2014-02-27|
    CA2783778A1|2013-02-24|
    EP2561979A3|2017-07-12|
    CA2783778C|2016-11-22|
    EP2561979B1|2018-12-26|
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    法律状态:
    2014-12-02| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
    2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-12-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-09-15| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-12-08| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 22/08/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/217,109|2011-08-24|
    US13/217,109|US8465613B2|2011-08-24|2011-08-24|Method and apparatus for fabricating variable gauge, contoured composite stiffeners|
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