![]() METHOD FOR MANUFACTURING AEROFOLIO AND APPLIANCE FOR MANUFACTURING AN AIRFORGE BOX
专利摘要:
method and apparatus for manufacturing large-scale integrated airfoils. the present invention relates to an airfoil is manufactured with the assembly of cured coverings with stringers featuring cured stringer blankets and uncured stringer strings. the coverings are attached to the stringers with the curing of the stringer strings. 公开号:BR102012031674B1 申请号:R102012031674-9 申请日:2012-12-12 公开日:2020-03-10 发明作者:Martin W. Hansen 申请人:The Boeing Company; IPC主号:
专利说明:
Descriptive Report of the Invention Patent for "METHOD FOR MANUFACTURING AIRFORCE AND APPLIANCE FOR MANUFACTURING AN AIRFORGE BOX". BACKGROUND INFORMATION 1. Field [001] The present invention relates, in general, to techniques and equipment to manufacture airfoils, such as wings and stabilizers, and deals more particularly with a method and apparatus for manufacturing large-scale integrated airfoils formed from composites. 2. Background [002] Large-scale composite airfoil structures, such as wing boxes, can be built using fasteners to mechanically assemble multiple composite components. The use of fasteners has a number of disadvantages, including, but not limited to, a larger number of parts, higher labor costs for holes and mounting fixtures, increased weight to the structure and the susceptibility of fasteners to lightning. [003] Some of the disadvantages of mechanical assembly using fasteners can be overcome with the integration of composite components to reduce the number of parts; however, the large-scale integration of composite structures can present several challenges. For example, although large-scale integration can reduce the number of parts, some parts may require special storage, handling and follow-up before a final bonding operation. These requirements can, in turn, increase work in process (WIP), tool speeds and freezer storage space. Also, the tooling required for large-scale integration can be relatively complicated, cumbersome and expensive. For example, it may be difficult to achieve the desired dimensional control of large-scale integrated structures without the use of complicated and costly combined matrix tools. In addition, the final connection tooling may require additional heavy and expensive reinforcement structures to withstand the forces imposed by autoclave processing. [004] Large-scale integrated structures may require a correspondingly large area of vacuum bagging, which may require intensive installation work, in addition to the possibility of leaks that can be difficult to detect and repair before curing. Yet another challenge posed by large-scale integration involves the fact that certain NDI (non-destructive inspection) operations can be performed only after the final cure. The NDI performed after the final curing step may not allow premature detection of parts that require rework, and may result in costly repairs or scrapping of a relatively large assembly or part due to non-conformity in a relatively small portion. [005] Consequently, there is a need for a method and apparatus for manufacturing large-scale integrated composite structures, such as airfoils, that reduce the need for large, costly and / or complicated tooling to maintain dimensional control over parts assembled, while reducing the amount of vacuum bagging that is required during final curing operations. There is also a need for a method and an apparatus, as mentioned above, that can allow the premature detection of parts that require rework before being integrated into a final structure and that can avoid the need to subject large assembled parts to pressure of autoclave. SUMMARY [006] The described embodiments provide a method and apparatus for manufacturing large-scale integrated composite structures, such as airfoils, which employ the combination of components in order to reduce or eliminate fasteners and obtain a desired dimensional stability with relatively light tooling Minimum. In one embodiment, airfoil boxes are manufactured using pre-cured stringer liners and blankets that are assembled with uncured stringer strings using relatively simple, low-cost tooling. Pre-cured liners and stringers are combined with simple internal tooling in an integrated way that allows them to function as the final bonding tool themselves. The final cure may require that autoclave forces be applied only to the area of the stringer strings, the need for the entire assembly to react to these large autoclave forces being reduced or eliminated. In some applications, depending on the material systems that are used, final curing can be performed at or near atmospheric pressure in an oven. The final curing tool does not require any OML (external mold line) definition or extensive support for large structures. During autoclave curing, the uncured stringer strings are free to move in response to autoclave pressure which causes the uncured stringer strings to adapt and be molded with respect to the IML (inner mold line) of the coating , thus providing a good fit between the stringers and the cladding. The use of pre-cured stringer liners and blankets, along with integrated tooling and special bagging techniques, simplifies large-scale final curing processing, while greatly reducing the amount of vacuum bagging and associated complex tools. Also, the integrated tooling allows the manipulation and indexing of thin parts, such as stringer strings, with reduced risk of damage, and provides a continuous support of great undefined, uncured details (eg stringer strings) with a need minimum for auxiliary equipment. The method and apparatus described allows the NDI of composite components prior to final bonding operations and can significantly reduce the need for rework. [007] Another advantage of the described embodiments is that the pre-cured coatings and stringers can finally be trimmed before final bonding operations. Large-scale integrated left and right structures can be built on the same final connection device. Vacuum bagging is simplified and can be performed using reusable bagging concepts. Final curing cycles can be significantly reduced compared to typical large integrated CFPR (carbon fiber reinforced plastic) structures because of the reduced weight of the final bonding tool. [008] According to a described embodiment, a method of making an airfoil is provided, which comprises forming a pair of cured composite linings, forming at least one stringer, including mounting uncured stringer strings and at least one composite stringer blanket cured, and mount cured and stringer linings and cure stringer strings. The method additionally comprises compacting the stringer strings against cured linings as the stringer strings are being cured. Mounting the liners and stringer includes retaining the stringer blanket and stringer strings on a tool, and mounting the liners on the tool with an internal mold line on each of the liners near the stringer strings. The retention of the stringer mat and stringer strings on the tool includes adhering the stringer strings to the stringer mat, and attaching the stringer mat to the tool. Mounting the cured linings and the stringer includes forming holes in each of the linings, and removably mounting the linings on the tool by inserting fasteners through the holes in the tool. Mounting the cured liners and the stringer can also include indexing the stringer relative to the cured liners by mounting the tool on the indexing rods. [009] According to another described embodiment, a method of making an airfoil box is provided. The method comprises providing a pair of cured composite coatings, each having a wingspan, and assembling at least one composite stringer, including connecting uncured composite stringer strings to a cured composite stringer blanket. The method additionally comprises retaining the cured stringer and coatings in an indexed mutual mounted relationship over span, and connecting the stringer to cured composite coatings by curing the uncured composite stringer strings. The method may additionally comprise generating a compaction force that compresses the stringer strings against the stringer blanket and linings as the stringer strings are being cured. The compaction of the stringer strings can be performed with the installation of vacuum bags on the stringer strips respectively, and with the evacuation of each of the vacuum bags. Stringer linings and blankets are used to react to the compaction force. [0010] According to yet another embodiment, the apparatus is provided to manufacture an airfoil box, which comprises a tool adapted to retain at least one stringer composed between two liners with uncured portions of the stringer close to the liners, and a device for support the tool while curing the uncured portions of the stringer. The tool includes a first and a second tool portion between which a stringer can be attached and to which the liners can be attached. Each tool portion includes at least one vacuum bag to compact the uncured portions of the stringer during curing. The device additionally includes a plurality of indexing rods that cross and support the tool. The tool features a clamp to secure the first and second tool portions against the stringer. [0011] In short, according to one aspect of the invention, there is provided a method of fabricating an airfoil, which includes forming a pair of cured composite linings, forming at least one stringer, including assembling uncured stringer strings and at least a cured stringer blanket cured, to mount the cured strings on the stringer, and to cure stringer strings. [0012] Advantageously, the method additionally includes compacting the stringer strings against cured linings. [0013] Advantageously, the method comprises assembling the liners and the stringer which includes retaining the stringer blanket and stringer strings on a tool, and mounting the coatings on the tool with an internal mold line of each of the linings near the strings stringer. [0014] Advantageously, the method comprises the retention of the stringer mat and stringer strings on the tool which includes adhering the stringer strings to the stringer mat, and attaching the stringer mat to the tool. [0015] Advantageously, the method comprises the assembly of the cured coatings and the stringer which includes forming holes in each of the coatings, and removably mounting the coatings on the tool with the insertion of pins through the holes in the tool. [0016] Advantageously, the method comprises the assembly of the cured coatings and the stringer which includes indexing the stringer in relation to the cured coatings with the assembly of the tool on the indexing rods. [0017] Advantageously, the method comprises assembling the liners and the stringer which includes retaining the stringer blanket and stringer strings on a tool, and mounting the coatings on the tool with an internal mold line of each of the linings near the strings of stringer, the compression of stringer strings against the linings being performed with the installation of vacuum bags on the tool that respectively cover the stringer strings, and with the evacuation of vacuum bags. [0018] Advantageously, the method comprises assembling the cured linings and the stringer which includes placing a tool on a mounting device, assembling the cured stringer mat and the uncured stringer strings on the tool, and transferring the tool presenting the mat stringer mounted and stringer strings in a curing device. [0019] Advantageously, the method comprises the assembly of the uncured stringer strings and at least one cured stringer mat that includes precompacting the stringer strings against at least one uncured stringer mat. [0020] Advantageously, the method comprises pre-compaction which includes placing rope compaction tools against pair strings respectively, and compacting rope compaction tools respectively against stringer strings. [0021] Advantageously, the method comprises assembling the liners and the stringer includes transferring the stringer and stringer compaction tools to an internal tool, and mounting the coatings on the internal tool with an internal mold line of each of the coatings close to the stringer strings, and curing stringer strings includes the use of stringer compaction tools to compact stringer strings against the liner and at least one stringer blanket. An airfoil manufactured by the method. [0022] In accordance with another aspect of the invention, a method of making an airfoil box is provided, which includes providing a pair of cured composite coatings, each having a wingspan, assembling at least one composite stringer, including connecting stringer strings Uncured composites to a cured stringer blanket, retain the stringer and cured liners in an indexed relationship mounted together over the span, and connect the stringer to the cured composite liners by curing the uncured composite stringer strings. [0023] Advantageously, the method additionally includes generating a compaction force that compresses the stringer strings against the stringer blanket and linings as the stringer strings are being cured. [0024] Advantageously, the method comprises compacting the stringer strings which includes installing vacuum bags respectively over the stringer strings, and evacuating each of the vacuum bags. [0025] Advantageously, the method comprises coatings and stringer blankets that are used to react to the compaction force. [0026] Advantageously, the method comprises assembling the stringer which includes layering and curing the composite stringer blanket, layering and forming the composite stringer straps, applying an adhesive to one of the stringer blanket and stringer straps, assemble the stringer blanket and stringer strands together, and compact the stringer blanket and stringer strings together. [0027] Advantageously, the method additionally includes mounting the stringer and liners, including placing the stringer mounted on a tool, connecting the liners to the tool, and transferring the assembled liners and stringer to a curing device. [0028] Advantageously, the method comprises curing which is performed by placing the curing device in an autoclave, and substantially subjecting only the stringer strings to autoclave pressure. [0029] According to another aspect of the invention, an apparatus is provided for making an airfoil box, including a tool adapted to retain at least one stringer composed between two liners with uncured portions of the stringer close to the liners, and a device for support the tool while curing the uncured stringer portions. [0030] Advantageously, the apparatus comprises a tool that includes the first and second portions between which a stringer can be attached and to which the linings can be connected. [0031] Advantageously, the apparatus comprises each of the tool portions that includes at least one vacuum bag to compact the uncured portions of the stringer during curing. [0032] Advantageously, the apparatus comprises the device which includes a plurality of alignment indexing rods that traverse and support the tool. [0033] Advantageously, the apparatus comprises the tool which includes a clamp to fix the first and second tool portions against the stringer. [0034] The characteristics, functions and advantages can be achieved independently in various embodiments of the present description or can be combined in still other embodiments in which additional details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0035] The new characteristics of the advantageous embodiments are presented in the appended claims. Advantageous embodiments, as well as a preferred mode of use, objectives and additional advantages thereof, will, however, be understood with reference to the following detailed description of an advantageous embodiment of the present description, when read in conjunction with the accompanying drawings, in which: [0036] figure 1 is an illustration of an aircraft showing airfoils manufactured in accordance with the described embodiments, [0037] figure 2 is an illustration of a section view taken along line 2-2 in figure 1, [0038 ] figure 3 is an illustration of a total functional block diagram of the apparatus for making airfoils according to the described embodiments, [0039] figure 4 is an illustration of a flow diagram of a method of making an airfoil, [0040 ] figure 5 is an illustration of an end view of the curing device and a pair of internal tools, the linings and stringers not shown for purposes of for clarity, [0041] figure 6 is an illustration of a side view taken in the direction shown as "6" in figure 5, [0042] figures 7A-7D are illustrations showing sequential steps for making the blanket ropes, [0043 ] figures 8A-8C are illustrations showing sequential steps for manufacturing the fillers, [0044] figures 9-12 are illustrations of cross-sectional views of a compaction tool assembly, showing the sequential steps for assembling and compacting the stringer components, [0045] figure 13 is an illustration of an end view of a stringer pre-assembly device while loading a lower portion of an internal tool, [0046] figure 14 is an illustration similar to figure 13, showing the lower tool portion fully loaded and representing a stringer mounted in the process of being loaded in the lower tool portion, [0047] figure 15 is a similar illustration to figure 14, but showing the upper portion of the internal tool in the process of being loaded into the pre-assembly device, [0048] figure 16 is an illustration similar to figure 15, but showing the upper tool portion having been loaded and representing the installation of a fixing sleeve collar, [0049] figure 17 is an illustration similar to figure 16, but it shows the fixing sleeve collar fully installed, and the stringer attached inside the internal tool, [0050 ] figure 18 is an illustration similar to figure 17, but showing the assembly of the internal tool and the attached stringer being lifted from the pre-assembly device, [0051] figure 19 is an illustration of an end view showing the internal tool and a stringer attached to the curing device, [0052] figure 20 is an illustration similar to figure 19, but showing a second internal tool and stringer attached in the process of being loaded watered in the curing device, [0053] figure 21 is an illustration of a side view similar to figure 6, but showing two stringers respectively attached to the internal tools shown in figure 20 and indexed along the length of the curing device, [ 0054] figure 22 is an illustration of a cross-sectional view showing the placement of index holes in the linings and two of the stringer blankets, [0055] figure 23 is an illustration of an end view of the curing device that shows the coatings in the process of being mounted on the internal tools, [0056] figure 24 is an illustration similar to figure 23, but showing the coatings placed against the internal tools and fastening pins that are ready for installation, [0057] a figure 24A is an illustration of the area designated as figure 24A in figure 23, and illustrating a gap between the stringer strings and the sheath, [0058] figure 25 is a the illustration similar to figure 24, but showing a support having been installed in the curing device, [0059] figure 26 is an illustration of a side view in the direction shown as "26" in figure 25, [0060] figure 27 is an illustration of an end view showing the airfoil box being removed from the curing device after final curing, [0061] figure 28 is an illustration of a side view showing the airfoil box being lifted from the curing device after the final cure, [0062] figure 29 is an illustration of a cross sectional view of the airfoil box, showing a disassembly tool being inserted into the internal tools, [0063] figure 30 is an illustration similar to figure 29 showing the disassembly tool having been removed and the clamping sleeves having been released from the internal tools, [0064] figure 31 is an illustration of a plan view of the airfoil box as the tools internal amentions are being removed from it, [0065] figure 32 is an illustration of a perspective view showing a rope compaction tool to aid in compression of the stringer rope, [0066] figures 33-36 are similar illustrations to figures 9-12, which show sequential steps to assemble and compact the stringer components using the rope compaction tool shown in figure 32, [0067] figure 37 is an illustration of a cross section of an alternate portion bottom of an internal tool adapted for use with the rope compaction tool shown in figure 32, [0068] figure 38 is an illustration similar to figure 37, but showing the stringer assembled in figure 36 being loaded in the lower portion of the internal tool shown in figure 37, [0069] figure 39 is an illustration similar to figure 38, but showing the upper portion of the internal tool being loaded into the stringer, [0070] figure 40 is an illustration similar to figure 39, but showing the internal tool fully mounted on the stringer, [0071] figure 41 is an illustration of a cross-sectional view of an alternative form of the strings stringer showing trimmed ends, [0072] figure 42 is an illustration of an end of a tapered stringer blanket along one side, [0073] figure 43 is an illustration similar to figure 41, but with untrimmed rope ends and which shows the use of the stringer blanket in figure 42, [0074] figure 44 is an illustration similar to figure 43, but that shows the use of a stringer rope with a flange with an internal taper coinciding with the tapering of the blanket stringer shown in figure 42, [0075] figure 45 is an illustration similar to figure 44, but showing a stringer blanket with a symmetrically tapered end and stringer strings internally tapered to match the tapered stringer blanket, [0076] figure 46 is an illustration of the components shown in figure 45, in an exploded form, [0077] figure 47 is an illustration of the area designated as figure 47 in figure 45, [0078] figure 48 is an illustration of another embodiment of a stringer rope featuring externally tapered flanges, [0079] figure 49 is an illustration of a flow diagram showing additional details of the method of making airfoil, [0080 ] figure 50 is an illustration of an aircraft production and service methodology flow diagram, and [0081] figure 51 is an illustration of an aircraft block diagram. DETAILED DESCRIPTION [0082] Referring first to figure 1, an aircraft 100 includes a fuselage 102 having one or more airfoils, which, in the illustrated example, comprise wings 104, horizontal stabilizers 106 and vertical stabilizer 108. Figure 2 illustrates a typical airfoil box 110 that can form a portion, for example and without limitation, of each of the wings 104 of the aircraft 100 shown in figure 1. The airfoil box 110 extends in the direction of the wingspan 105 shown in figure 1 (on the cover in figure 2 ) of a wing 104, and broadly includes one or more struts 112 sandwiched between a pair of outer linings 114. The struts 112 as well as the outer linings 114 may each comprise a fiber-reinforced laminated composite, such as, without limitation , carbon fiber epoxy. [0083] The stringers 112 can be spaced apart in the direction of direction of the string 128 at a suitable distance to meet the requirements of the drawing. Each of the stringers 112 includes a stringer blanket 116 that lies on a plane that extends across the wing linings 114. Each of the strings 112 additionally includes a pair of stringer strings 118 at the opposite ends of the stringer blanket 116. Each of the strings stringer 118 is generally L-shaped in cross section and includes flanges 120, 122. As will be discussed in greater detail below, each of flanges 122 is connected to stringer mantle 116 and each of flanges 120 is connected to IML (line internal mold) 115 of one of the linings 114. Each of the stringer blankets 116 includes an indexing hole 126 in an average area thereof for the purposes of which will be discussed below. A radius filler 124 formed of composite material or a suitable adhesive fills a space between the end of a stringer blanket 116, and the stringer strings 118 and the liner 114 in order to strengthen the connection between the struts 112 and the linings 114. Figure 2 and the figures subsequently discussed illustrate the airfoil box 110 as being substantially flat; however, the airfoil box 110, including stringer blankets 116 and / or linings 114, will typically be contoured in one or more directions, including being curved along the direction of span 105 (figure 1) and along the direction in the direction direction of the rope 128 shown in figure 2. [0084] Now, attention is turned to figure 3 which broadly illustrates the apparatus 135 for making composite airfoils, such as the airfoil box 110 shown in figure 2. The apparatus 135 broadly comprises one or more internal tools 138 and a device curing 140. A stringer 112 comprising a stringer blanket 116 and "green" stringer strings 118 is attached to an internal tool 138. The linings 114 are then temporarily attached to the internal tool 138, relative to the stringer 112 along from the direction to the span 105 (figure 1) of the airfoil box 110. The assembly of the stringer 112 and the liners 114 is loaded into a curing device 140 and the entire assembled structure can be placed in an autoclave for final curing. As will be discussed in more detail below, stringer blanket 116 as well as linings 114 are pre-cured, and stringer 118 strands will be cured when the entire assembled structure is placed in the autoclave for final curing. Alternatively, depending on the material systems that are used in a specific application, final curing can be performed in or near an atmospheric pressure furnace (for example, 103.42 KPa (15 psi)). [0085] Figure 4 broadly illustrates the steps of a method of making a composite airfoil, such as airfoil box 110 shown in figure 2. From 130, composite linings 114 are formed and pre-cured. Similarly, in 131 one or more composite stringer blankets are formed and pre-cured. Coverings 114 and stringer blankets 116 can be manufactured using conventionally manufactured composite laminate manufacturing techniques, including automated or manual folding. Then, at 132, at least one stringer 112 is formed with the connection of uncured stringer strings 118 and fillers 124 in a pre-cured stringer blanket 116. In step 134, pre-cured linings 114 and a stringer 112 are assembled. Stringer strings 118 are compacted against linings 114. Finally, in step 136, stringer strings 118 are cured, thus linking them to both the pre-cured stringer blanket 116 and the pre-cured linings 114. [0086] Now, attention is turned to figures 5 and 6 which illustrate additional details of the internal tools 138 and the curing device 140. In this example, a pair of internal tools 138 is shown; however, in other embodiments, a greater or lesser number of an internal tool 138 may be employed, depending on the number of stringers 112 used in the airfoil box 110 (figure 2). Each of the internal tools 138 comprises a first and a second halves or portions 138a, and 138b, which, for convenience, will be referred to below as an upper tool portion 138a and a lower tool portion 138b. The upper and lower tool portions 138a, 138b are coupled together by a removable fixing sleeve 144 which includes a fixing sleeve collar 146. [0087] The curing device 140 includes a plurality of spaced indexing rods 154 supported on a base 150. The indexing rods 154 support and index the internal tools 138 along the entire length of the curing device 140 in multiple locations. The internal tools 138 extend throughout the wingspan of the airfoil box 110. As will be discussed below, the internal tools 138 cannot be subjected to autoclave forces during the final curing process. The internal tools 138 have external surfaces 226 which are curved, as required, to substantially match the curvature of the linings 114. The curing device 140 may additionally include a prop 152 to support the indexing rods 154 and the internal tools 138, as required. required. It will be noted here that, in the illustrated example, the internal tools 138 and the curing device tool 140 do not require any structure defining the IML (external mold line) of the airfoil box 110, since the OML is defined by the pre coatings -cured 114. [0088] As will become evident later, the indexing rods 154, the base 150 and the support 152 provide essentially a relatively simple retention device for holding the internal tools 138 in an indexed position along the direction of span 105 ( figure 1) of the airfoil box 110 during final curing. Each of the upper and lower tool portions 138a, 138b includes a recess generally in the form of L 142 for purposes which will become apparent later. Indexing stops 148 attached to the indexing rods 154 determine the vertical position of each of the internal tools 138 in the curing device 140. [0089] Referring now to figure 7A, each of the stringer strings 118 shown in figure 2 can be manufactured by assembling a multi-ply flat lay arrangement 159, using, for example, numerically controlled automated processes such as an automatic fiber laying machine. Other layering techniques are possible. With reference to figure 7B, the flat layer 158 can be formed by dropping in hot folds on a suitable forming block 160, to form the flat layer 158 in the desired shape of the stringer rope 118e. Other training techniques may be possible. Then, as shown in figure 7C, a layer of adhesive 161 can be applied over the formed stringer rope 118, after which, as shown in figure 7D, the stringer rope 118 can be removed from the forming block 160 and trimmed, as desired, in its green or uncured state. Alternatively, the adhesive layer 161 can be applied to the stringer blanket 116, when the stringer components 112 are assembled, as discussed below in connection with figure 9. [0090] Figures 8A-8C illustrate a method for forming the fillers 124. As shown in figure 8A, a length of a filler material 124, which may comprise an adhesive or a laminate, is placed in the matrix cavity 166 of a die block 164. Then, as shown in figure 8B, a suitable tool 168 is used to press the filler material 124 into the die cavity 166, thereby forming the filler material 124 to the desired cross-sectional shape. With reference to figure 8C, the preformed filler 124 can be removed from the matrix block 164 and trimmed, as desired, in its green or uncured state. [0091] Figures 9-12 sequentially illustrate a suitable technique for pre-assembling the stringer 112 components using a compacting tool assembly 165, and pre-compacting the stringer strings 118 against the stringer blanket 116. The assembly of compacting tool 165 comprises upper and lower forming blocks 170, 172, and side forming blocks 176, 178. The compacting tool assembly 165 additionally includes a plurality of spaced center alignment pins 180 secured to the lower block 172 which are aligned with corresponding holes 174 in the upper block 170 and received within these. The spacing and size in cross section and the shape of the alignment pins 180 substantially correspond to those of the indexing rods 154 shown in figures 5 and 6. [0092] The stringer mat 116 may comprise a cured flat composite laminate having a plurality of spaced central openings 126 which respectively receive the alignment pins 180 to align the cured stringer mat 116 in the compaction tool assembly 165. A cured stringer blanket 116, uncured fillers 124 and uncured stringer 118 strands are assembled, as shown in figure 9, after which, as shown in figure 10, the forming blocks 170, 172, 176, 178 are used to pre-compact the stringer 112 components. Forming blocks 170, 172, 176 can be compacted using conventional vacuum bags (not shown) or pressing devices (not shown). Adhesive 161 (figures 7C, 7D) helps retain the uncured stringer strings 118 on the cured stringer blanket 116 as stringer strings 118 are being compressed against stringer blanket 116 and padding 124. After compaction, the upper formation block 170 is raised, as shown in figure 11, allowing the assembled stringer 112 to be removed from the lower formation block 172 and the alignment pins 180, as shown in figure 12. As will be discussed later in greater detail details, stringer strings 118 are adhered to stringer blanket 116 in locations such that stringer strings 118 are slightly recessed from the IML (inner mold line) 115 (figure 2) of linings 114 to ensure that there is no interference from adjust when they are assembled together. [0093] Figure 13 illustrates a pre-assembly device 200 that is used to pre-assemble each of the stringers 112 with the internal tooling 138 (figure 5). The pre-assembly device 200 comprises a plurality of rods 204 mounted on a base 202 in indexed locations spaced apart that correspond to the locations of the indexing rods 154 shown in figure 5. Each of the rods 204 includes a stop 148. Each of the gloves clamp 144 is slid over a corresponding rod of rods 204 and is vertically located by one of the stops 148. As shown in 155, strips of vacuum bags 100 that respectively extend the length of the internal tool 138 are sealed in the lower tool portion 138b by double seals 192, covering the recesses 142. Then the vacuum bags 190 are installed in the lower inner tool portion 138b, the tool portion 138b is loaded 198 onto the pre-assembly device 200, with the rods 204 passing through the central internal openings 194 in the internal tool portion 138b. A vacuum is drawn into the vacuum bags 190, causing them to be drawn against the recessed portion 196 of the internal tool portion 138b. Dragging the vacuum bags 190 against the tool portion 138a thus ensures that the vacuum bags 190 do not interfere with the subsequently assembled components until they are ready for final curing. Then, as shown in figure 14, the mounted stringer 112 is loaded onto the internal tool portion 138b and indexed by the rods 204 along the entire length of the stringer 112. [0094] With reference now to figure 15, strips of vacuum bags 190 are installed in the internal tool portion 138a and sealed there by double seals 200, resulting in the trap of the stringer blanket 116 between the opposite faces 214, 216 of the portions of internal tool 138a, 138b, respectively, as best seen in figure 16. A fixing sleeve collar 146 is installed 212 on fixing sleeve 144, locking the internal tool portions 138a, 138b together with the stringer 112 between them, as shown in figure 17. After this fastening procedure, as shown in figure 18, the entire internal tool 138 together with the attached stringer 112 can be removed from the pre-assembly device 200. It should be noted here that the need for vacuum bagging of the linings 114 or of the stringer blankets 118 is prevented according to the described embodiments, since they are pre-cured. Consequently, the total vacuum bagging area (restricted to the stringer 118 area) is substantially minimized. [0095] With reference now to figure 19, the internal tool 138 together with the attached stringer 112 is then transferred to the curing device 140 and slid downwards 220 over the indexing rods 154 until the lower collars 144a of the fixing gloves 144 engage the stops 148. As shown in figures 20 and 21, a second internal tool 138 'together with another attached stringer 112 can be loaded onto the curing device 140, and positioned against a second set of stops 148 on the indexing rods 154. A Figure 21 illustrates the positions of the internal tools 138, 138 'and the spars 112 after this assembly process. As previously discussed in connection with figures 5 and 6, the multiple indexing rods 154 support the internal tools 138, and are aligned in such a way that they index the internal tools 138 along the entire length of the curing device 140 in multiple locations. [0096] With reference now to Figure 22, as mentioned above, each of the stringer blankets 116 has a plurality of central openings 126 that index the stringer blanket 116 along the wingspan of the airfoil box 110. The indexing holes 114a are then formed by any suitable process, such as by drilling into linings 114. As shown in figure 23, index holes 114 and linings 114 are aligned with the outer surfaces 226 of each of the internal tools 138. Linings 114 are aligned with the external surfaces 226 of each of the internal tools 138. The linings 114 are mounted 224 against the external faces 226 of the tools 138, after which, as shown in figure 24, the fastening pins 228 are inserted through the indexing holes 114a through in order to disengage connect the linings 114a to the internal tools 138. The pins 228 can comprise, for example example and without limitation, ball-type locking pins. Referring to Figure 34A, as previously mentioned, stringer strings 118 can be slightly spaced from the IML 115 of the linings 114 to form a light span "G". The "G" gap helps to ensure that the linings 114 are seated flush against the outer faces 226 of the tools 138, without interference that could be caused by a possible contact with the stringer 118 strings. [0097] With reference now to figures 25 and 26, after the linings 114 are connected to the internal tools 138, the mainstay 152 can be installed in the curing device 140 in order to stabilize the internal tools 138 along the entire length of the tool device 140, in preparation for final curing operations. [0098] With reference again to figure 24A, in preparation for the final curing process, the vacuum previously extracted in the vacuum bags 190 is inverted, causing the bags 190 to compress the stringer strings 118 against the stringer blankets 116 and the liners 114. In this way, it can be appreciated that the bag compaction force is reacted substantially only by the stringers 112 and the liners 114. The curing device 140 can be placed in an autoclave (not shown) to cure the stringer strings uncured 118 as they are being compacted against stringer blankets 116 and lining 114. The compaction force applied to stringer 118 strings by vacuum bags 190, together with autoclave pressure (when required), force the flanges 120 (figure 2) of the stringer 118 strings against the IML 115 of the linings 114, shaping and molding the stringer 118 rope in any variations or curves actions (not shown) on IML 115. The combination of curing device 140 and internal tools 138 maintains the indexed positions of stringers 112 and linings 114 throughout the final cure. In addition, the use of internal tools 138 in combination with the curing device 140 provides solid support and reinforcement for the uncured stringer strings 118 throughout the assembly and curing process, with minimal need for auxiliary equipment. As a result, the possibility of damage to fragile parts, such as stringer 118 strings, is greatly reduced or eliminated. [0099] Referring now to figure 27, after the final cure, the upper stringer indexing stop 148 can be removed 231, allowing the airfoil box 110 together with the internal tools 138 to be slid 232 to the indexing rods 154 and raised 235 from the curing device 140, as shown in figure 28. [00100] With reference now to figure 29, the internal tools 138 can be removed from the airfoil box completed 110 with the insert 240 of the shank 236 of a disassembly tool 234 through the fixing sleeves 144. The disassembly tool 234 can include a cable 238 that can be rotated to unlock and release the fixing sleeve collars 146b. As shown in figure 30, with the fixing sleeve collars 146 loose, the fixing gloves 144 can be disassembled and removed from the internal tools 138 using the disassembly tool 234. Pins 228 are removed to detach the linings 114 from the internal tools 138, allowing the internal tools 138 to be removed 244 through the inner end 255 of the airfoil box 110, as shown in figure 31. Depending on the application, some degree of air draft (not shown) can be provided between the internal tools 138 and ILM 115 of liner 114 to facilitate removal of internal tools 138. Vacuum bags 190 can also be removed and removed 244 through inner end 255. After removing pins 228, holes 114a (figure 22) can be filled with suitable fasteners or a padding (not shown). Optionally, the ends (not shown) of the stringer strings 118 may need to be trimmed after removing the internal tools 138. [00101] Depending on the application, it may be necessary or desirable to apply additional compaction pressure to the stringer 118 strings as they are being mounted on the stringer blankets 116 and / or during final curing. In such applications, a rope compaction tool shown in figure 32 can be employed to apply direct compaction pressure to each of the green stringer strings 118. Figures 33-36 illustrate an alternative form of a similar compaction tool assembly 245 to the compacting tool assembly 165 shown in figures 9012, which employs the rope compacting tool 246. The compacting tool assembly 245 includes upper and lower forming blocks 170, 172 and side forming blocks 176, 178, together with four of the rope compaction tools 246. The rope compaction tools 246 are received inside the preformed stringer 118 and each includes an outer corner provided with spokes 246a (figure 34) that can assist in training and compaction of the internal radius of the stringer rope 118. Each of the rope compaction tools 246 additionally included there is a chamfered side 246b to which chamfering pressure 170a, 172a is applied in the upper and lower forming blocks 170, 172, respectively. [00102] After compacting the stringer 112 shown in figure 34, the upper forming block 170 is raised 248 and the side forming blocks 176, 178 are separated 250, as shown in figure 35, allowing the stringer 112 to be raised 252 of the lower formation block 172, as shown in figure 36. The rope compaction tools 246 may remain mounted with the stringer 112, when the compacted stringer 112 is lifted 252 from the lower formation block 172 and transferred to the lower portion 138b of the internal tool illustrated in figures 37-40. The upper and lower internal tool portions 138a, 138b shown in figures 37-40 are similar to those previously described in connection with figures 13-20; however, in this example, each of the internal tool portions 138a, 138b includes a chamfered corner 254 which is adapted to engage the chamfered side 246b (figure 32) of the rope compaction tools 246. After the stringer 112 is loaded in the lower inner tool 138b, as shown in figure 38, the upper inner tool portion 138a is loaded onto stringer 112, as shown in figure 39. After this assembly process, stringer mat 116 is fixed between opposite surfaces 214, 216 of the upper and lower tool portions 138a, 138b, respectively, as shown in figure 40. [00103] Referring now to figure 41, in some applications, the compaction pressure applied to stringer 118 strings may undesirably distort the reinforcement fibers at the outer ends of flanges 120, 122. In order to prevent such fiber distortion and ensure a pressure more evenly applied to the ends of the stringer strings 118, the outer edges 260 of the flanges 120, 122 can be trimmed with a taper after the stringer strings 118 are preformed in their green state in the process previously described in connection with figures 7A-7D. [00104] Figures 42 and 43 illustrate an alternative shape of the stringer 112, in which one side of each outer end 116b of the stringer blanket 116 is tapered at 116c. In this example, the flange 122 of one of the stringer strings 118 is tilted at an angle Θ with respect to the central axis 262 of the stringer blanket 116 in order to be flush with the taper 116c in the stringer blanket 116a. [00105] Figure 44 illustrates another embodiment of stringer 112 similar to that shown in figure 43; however, in this example, the outer side 122b of the flange 122 is tapered at an angle Θ substantially identical to the tapered inner side 122a of the opposite flange 122. [00106] Figures 45-47 illustrate yet another embodiment of a stringer 112. In this example, the outer end 116b of the stringer blanket 116b is symmetrically folded-tapered to substantially match the tapered inner sides 122a of each of the flanges 122. [00107] Figure 48 illustrates another variation of the stringer rope 118 in which the outer sides 120b, 122b of the flanges 120, 122 are each tapered internally. [00108] Attention is now turned to figure 49 which illustrates the additional details of the method of manufacturing an airfoil, discussed earlier. In 264, linings 114 and stringer blankets 116 are layered and then cured in 266. In 268, linings 114 and stringer blankets 116 can be trimmed, and inspected, as needed. In 270, indexing holes 114a can be formed in the linings and stringer blankets at indexing locations. In 272, the stringer 118 strings are layered, and in 274 the stringer 118 strands are formed in the desired cross-sectional shape. In 276, adhesive can be applied to stringer 118 strings, and in 278, radius 124 fillers can be formed. In 280, the stringers 112, comprising the stringer blanket 116, the stringer strings 118 and the fillers 124 are assembled and compacted together. In 282, the vacuum bags of strip 190 are installed and sealed in the internal tools 138, and in 284, the internal tools 138 are loaded in a pre-assembly device 200. [00109] In 286, a vacuum is applied to the vacuum bags 190 that drag the bags against the internal tools 138. In 288, the pre-assembled stringers 112 are loaded into the internal tools 139, and in 290, the stringers 112 are stuck in the internal tools 138. In 292, the combination of the attached stringers 112 and the internal tools 138 is removed from the pre-assembly device and transferred to a curing device 140, where the stringers 12 are indexed along their entire wingspan. In step 294, the linings 114 are temporarily attached to the internal tools 138. Then, in 296, the retainer 152 can optionally be installed in the curing device 140, and in 298, the vacuum in the vacuum bags 190 is inverted, thus compacting stringer strings 118 against linings 114 and stringer blankets 116. [00110] At 300, curing device 140 together with stringers 112 and assembled linings 114 are loaded into an autoclave or similar curing oven, and at 302, stringer 118 strands are cured. At 304, curing device 140 is removed from the autoclave or oven, and at 306, cured aerofoil box 110 is removed from curing device 140. At 308, internal tools 138 and vacuum bags 190 are removed from the cured airfoil box 110, and at 310, the index holes 114a in the liner 114 are filled with fasteners or a pad. Finally, in 312, the stringer strings 118 can finally be trimmed, as required, and the airfoil box 110 can be non-destructively inspected. [00111] Referring now to figures 50 and 51, embodiments of the description can be employed in the context of an aircraft manufacturing and service method 314, as shown in figure 50, and aircraft 316, as shown in figure 50. First, back to Fig. 50, an illustration of an aircraft manufacturing and service method 314 is shown according to an advantageous embodiment. During pre-production, the aircraft manufacturing and service method 314 may include the specification and design 318 for aircraft 316 in figure 51 and material acquisition 320. [00112] During production, the manufacture of components and subassembly 322 takes place and the integration of system 324 of aircraft 316 in figure 51 takes place. After that, aircraft 316 in figure 51 can pass certification and distribution 326 in order to be placed in service 328. While in service 328 by a customer, aircraft 316 in figure 51 is scheduled for maintenance and service 330, which can include modification, reconfiguration, renewal, and other maintenance or service. [00113] Each of the 314 aircraft manufacturing and service method processes can be performed by a system integrator, a third party and / or an operator. In these examples, the operator can be a customer. For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and system subcontractors, a third party may include, without limitation, any number of vendors, subcontractors, and suppliers, and an operator may be a airline, a leasing company, a military entity, a service organization, etc. [00114] Referring now to figure 51, an illustration of an aircraft 316 is shown in which an advantageous embodiment can be implemented. In this example, aircraft 316 is produced by aircraft manufacturing and service method 314 in Fig. 50 and may include aircraft structure 332 with a plurality of systems 334 and interior 336. Examples of systems 34 include one or more of these: system propulsion system 338, electrical system 340, hydraulic system 342, or environmental system 344. Any number of other systems can be included. Although an aerospace example is shown, different advantageous embodiments can be applied to other industries, such as the marine and automotive industries. [00115] Apparatus and methods realized here can be used during at least one of the stages of the aircraft manufacturing and service method 314 in figure 50. In an illustrative example, components or subassemblies produced in the manufacture of components and subassembly 322 in the figure 50 can be manufactured in a similar way to the components or subassemblies produced while the aircraft 316 is in service 328 (figure 50). As yet another example, numerous embodiments of the apparatus, embodiments of the method, or a combination of these can be used during the stages of production, such as the manufacture of components and subassembly 322 and system integration 324 in figure 50. A number, when refers to items, indicates one or more items. For example, a number of embodiments of the apparatus are one or more embodiments of the apparatus. Numerous embodiments of the apparatus, embodiments of the method, or a combination of these can be used while aircraft 326 is in service 328 and / or during maintenance and service 330 in figure 50. The use of numerous different advantageous embodiments can substantially promote assembly and / or reduce the cost of the 316 aircraft. [00116] The description of different advantageous embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the manner described. Many modifications and variations will be evident to those skilled in the art. In addition, different advantageous embodiments can provide different advantages as compared to other advantageous embodiments. The selected embodiment or embodiments are chosen and described in order to better explain the principles of the embodiments, the practical application, and to allow others skilled in the art to understand the description for the various embodiments with various modifications, as appropriate to the specific use contemplated. .
权利要求:
Claims (13) [1] 1. Method of making an airfoil, characterized by the fact that it comprises: forming (130) a pair of cured composite coatings (114), forming (132) at least one stringer (112), including assembling uncured stringer strings (118 ) and at least one cured stringer blanket (116); mount (134) the Kurdish linings on the stringer; and cure (136) the stringer strings. [2] 2. Method according to claim 1, characterized by the fact that it additionally comprises: compacting the stringer strings (118) against the cured linings (114). [3] 3. Method according to claim 1 or 2, characterized in that the assembly (134) of the linings (114) and the stringer (112) includes: retaining the stringer blanket (116) and the stringer strings ( 118) on a tool (138), and mount the linings (114) on the tool (138) with an internal mold line (115) of each of the linings (114) spaced from the stringer strings (118). [4] 4. Method according to claim 3, characterized by the fact that the retention of the stringer mat and stringer strings on the tool includes: adhering stringer strings (118) to the stringer mat (116), and fixing the stringer blanket (116) on the tool (138). [5] 5. Method according to any one of the preceding claims, characterized by the fact that the assembly of the cured coatings and the stringer includes: forming holes in each of the coatings (114), and removably mounting the coatings (114) on the tool (138 ) with the insertion of pins through the holes in the tool. [6] 6. Method, according to any previous claim, characterized by the fact that the assembly (134) of the Kurdish coatings (114) and the stringer (112) includes the indexing of the stringer in relation to the cured coatings with the tool mounting on the rods indexing. [7] 7. Method, according to any previous claim, characterized by the fact that: the assembly (134) of the linings (114) and the stringer (112) includes retaining the stringer blanket (116) and stringer strings (118) on a tool (138), and mount the linings on the tool with an internal mold line (115) of each of the linings close to the stringer strings, and the compaction of the stringer strings (118) against the linings is performed with the installation of vacuum bags (140) in the tool that respectively cover the stringer strings (118), and with the evacuation of vacuum bags (140). [8] 8. Method according to the claim, characterized by the fact that the assembly (134) of the cured linings and the stringer includes: placing a tool (138) in a mounting device; assemble the cured stringer mat (116) and the uncured stringer strings (118) onto the tool (138), and transfer the tool (138) with the stringer mat (116) and stringer strings (118) mounted and stringer strings (118) for a curing device. [9] 9. Method according to any one of the preceding claims, characterized in that the assembly of the uncured stringer strings and at least one cured stringer blanket (118) includes pre-compacting the stringer strings (118) against at least one uncured stringer blanket (116). [10] 10. Method according to claim 9, characterized by the fact that pre-compaction includes: placing the rope compaction tools respectively against the stringer strings, and compacting the rope compaction tools respectively against the stringer strings , where mounting of the liners and stringer includes transferring the stringer and stringer compaction tools to an internal tool, and mounting the linings on the internal tool with an internal mold line from each of the liners near the stringer strings, and wherein curing stringer strings includes using compaction tools to compact stringer strings against the liner and at least one stringer blanket. [11] 11. Apparatus (135) for manufacturing an airfoil box (110), comprising: a tool (138) adapted to retain at least one composite stringer (112) between two liners (114) with uncured stringer portions of the liners (114); and a device (140) for holding the tool (138) while curing the uncured portions of the stringer (112), wherein the tool (138) includes a first and a second portion (138a, 138b) including a stringer can be attached and to which the liners can be connected, and characterized by the fact that each of the tool portions includes at least one vacuum bag (190) to compact the uncured portions of the stringer during curing. [12] Apparatus according to claim 11, characterized by the fact that the device includes a plurality of alignment indexing rods that cross and support the tool (138). [13] 13. Apparatus according to claim 11 or 12, characterized in that the tool (138) includes a clamp for securing the first and second tool portions (138a, 138b) against the stringer.
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引用文献:
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法律状态:
2015-01-20| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]| 2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]| 2019-08-27| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]| 2019-12-31| B09A| Decision: intention to grant [chapter 9.1 patent gazette]| 2020-03-10| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 12/12/2012, OBSERVADAS AS CONDICOES LEGAIS. |
优先权:
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申请号 | 申请日 | 专利标题 US13/324,254|2011-12-13| US13/324,254|US9017510B2|2011-12-13|2011-12-13|Method and apparatus for fabricating large scale integrated airfoils| 相关专利
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