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    • 专利摘要:
    “APPLIANCES TO PRODUCE AN ACOUSTIC STRUCTURE, FOR AUTOMATIC PRODUCTION OF AN ACOUSTIC CORE, AND TO INSTALL AN ACOUSTIC DEVICE AND THEIR METHODS” A laser (62) cuts overlapping tapes (58) of acoustic material (58) in acoustic devices (34) . A manipulator that is automatically controlled (66) includes an end effector (60) that features groups of placement tools (68) for simultaneously placing multiples of those acoustic devices (34) in a cell nucleus (32). Those placement tools (68) include mandrels (104) provided with vacuum sensors to capture and retain the acoustic devices (34) during transport to the core (32). A visualization system aligns the placement tools (68) with the cells (42) of the core (32). Such end effector (60) further includes a thermal radiation device (138) for connecting the acoustic devices (34) to the core (32).
    公开号:BR102015014080B1
    申请号:R102015014080-0
    申请日:2015-06-15
    公开日:2020-12-29
    发明作者:Eric Herrera；Noel Timothy Gerken；John Scott Bauman
    申请人:The Boeing Company；
    IPC主号:
    专利说明:

    1. Field:
    [001] The present invention generally relates to acoustic structures and deals more particularly with a method and apparatus for installing acoustic devices in cell nuclei. 2. Basics:
    [002] Acoustic structures are used in a wide variety of applications to attenuate noise. For example, one type of an acoustic structure used to reduce noise in aircraft engines is an internal acoustic coating comprising a panel construction in which a cell core is sandwiched between a perforated inner film and an unperforated outer film. The cell nucleus may have a septum in each of the cells in order to increase the acoustic performance of the inner lining.
    [003] There are at least three known methods for septorization of alveolar nuclei, each of which is time-consuming and laborious, in part because each septum must be individually placed in a nucleus cell. The first method requires dividing the nucleus and using an adhesive to bond a septum layer between the divided nuclei. The second method involves a lost wax process that creates a buried septum, where an alveolar nucleus is pressed into the wax. A thin layer of liquid resin floats over the top of the wax, which is then cured to form a solid layer and the wax is melted out of the honeycomb core. The third method involves using an automated robotic process where individual septum pieces with tongues are inserted one by one into each alveolar cell. The tongues of the individual septum pieces are attached to the alveolar cell walls by carefully immersing the alveolar panel to a certain depth in a liquid adhesive.
    [004] Consequently, there is a need for a method and apparatus for placing acoustic devices such as septa in a cell nucleus that is both fast and cost-effective. There is also a need for a method for producing acoustic structures that is more highly automated and efficient than was previously possible. SUMMARY
    [005] The described modalities provide a fully automated method and apparatus for the production of acoustic structures such as nuclei with septa used for sound control. The acoustic structures are produced using a computer-controlled laser to cut acoustic material into a desired shape and perimeter of the acoustic and solar device the material. Large numbers of acoustic devices, such as septa, can be quickly inserted into the cells of a cell nucleus and turned on in place under full automatic control. A visualization system and digital controls of the machine ensure precise alignment and precise placement of the acoustic devices in the core.
    [006] According to a described embodiment, an apparatus is provided for producing an acoustic structure having a nucleus with a plurality of cells. An end effector is mounted on the manipulator and includes a plurality of acoustic device placement tools each capable of placing an acoustic device in one of the nucleus cells. A digital controller includes a set of digital instructions to control the movement of the manipulator and the operation of the end effector. The acoustic device placement tools are arranged on opposite and opposite banks of the same. Each of the acoustic device placement tools is mounted on the end effector for pivoting movement between an acoustic device pickup position and an acoustic device placement position. Each of the acoustic device placement tools includes a mandrel capable of being inserted into the acoustic device and a vacuum sensor to retain an acoustic device over the mandrel. Each of the acoustic device placement tools further includes a plurality of fingers movable to one end of the acoustic device to conform the end of the acoustic device to mate with the cells. The apparatus further comprises a visualization system to guide the end effector and to align each of the acoustic device placement tools with one of the core cells. The visualization system includes a laser mounted on the end effector to direct a laser point on the nucleus and a camera mounted on the end effector to view the cells of the nucleus. The apparatus also includes a material supply system for supplying overlapping tapes of acoustic material and tapes of adhesive material that overlap and adhere to tapes of acoustic material. A laser coupled with the digital controller cuts the acoustic tapes in an acoustic device format. A curing device coupled with each of the acoustic device placement tools cures the adhesive tapes. The curing device may comprise a thermal radiation generator capable of directing thermal radiation onto the adhesive tape.
    [007] According to another described embodiment, an apparatus is provided for automated production of an acoustic core having a plurality of cells. The apparatus comprises a material supply system to supply acoustic material tapes and a laser to convert the tapes into a plurality of acoustic devices. The apparatus also includes an end effector to capture the acoustic devices and place the acoustic devices in the cells and a controller coupled with the laser and the end effector. The material supply system includes two reels of acoustic tapes capable of being pulled out of the reels in an overlapping relationship with each other. The material supply system also includes two reels of adhesive tapes capable of being pulled out from the reels in a laterally spaced relation to each other and overlapping the tapes of acoustic material. The controller is capable of controlling the operation of the laser and includes a set of programmed instructions that direct the laser to cut the acoustic devices from the strips of acoustic material. The end effector includes a plurality of acoustic device placement tools each capable of placing an acoustic device in one of the core cells. Each of the acoustic device placement tools includes a mandrel insertable in one of the acoustic devices and a vacuum system coupled with the mandrel and capable of generating a vacuum within the acoustic device to retain the acoustic device over the mandrel. Each of the acoustic device placement tools may include a shaper that is displaceable to one end of the acoustic device to conform the end of the acoustic device to match the cell wall geometry. The apparatus additionally comprises a visualization system coupled with the controller to align the acoustic device placement tools with each of the core cells.
    [008] According to a described modality, an apparatus is provided to install an acoustic device generally hollow in a cell of a cell nucleus. The apparatus includes a tool capable of being inserted into the acoustic device and a vacuum sensor on the tool capable of holding the acoustic device against the tool. A former on the tool is operative to conform an end of the acoustic device to substantially match the geometry of the cell. The tool is elongated and tapered along its length and the shaper includes fingers that can be slid over the tool and into the acoustic device. The fingers are circumferentially spread out from each other and around the tool. Each of the fingers has an outer tip shaped to form an end of the acoustic device to substantially match the shape of the cell. The apparatus additionally comprises a radiation generator coupled with the tool and capable of directing radiation to the acoustic device during the installation of the acoustic device in the cell.
    [009] According to another described modality, an apparatus is provided to manufacture a plurality of acoustic devices adapted to be installed in a cell nucleus. The apparatus includes a supply of adhesive to connect each of the acoustic devices to the core, as well as a supply of sheets of acoustic material. The apparatus also includes a cutter for cutting the sheets of acoustic material into a desired shape and a joining device for joining the sheets of acoustic material together. The adhesive supply includes at least one tape of adhesive material capable of being pulled over the sheets of acoustic material. The supply of sheets of acoustic material includes first and second strips of acoustic material aligned to be pulled in overlapping relationship with each other. The cutter and the joining device can comprise an automatically controlled laser.
    [0010] According to yet another described embodiment, a method for producing an acoustic nucleus having a plurality of cells is provided. The method comprises making a plurality of acoustic devices, capturing groups of the acoustic devices, placing the groups of the acoustic devices respectively in cells of the nucleus and connecting the acoustic devices to the nucleus. The manufacture of acoustic devices is performed by overlapping tapes of acoustic material and laser cutting the tapes in a shape of the acoustic devices and welding between them those of the tape surrounding at least a portion of each of the acoustic devices. Capturing groups of acoustic devices includes inserting a plurality of chucks respectively in the acoustic devices and retaining the acoustic devices on the chucks using a suction force. Placing the groups of the acoustic devices respectively in cells of the nucleus is performed using a visualization system to align the acoustic devices with the cells. Connecting the acoustic devices to the nucleus includes directing thermal radiation over the acoustic devices after the acoustic devices have been placed in the nucleus.
    [0011] According to another described embodiment, a method is provided for installing a generally hollow acoustic device in a cell of a cell nucleus. A tool is inserted into the acoustic device and a vacuum is used to retain the acoustic device over the tool. A shaping process is used to shape one end of the acoustic device to match a shape of the cell. The method also includes capturing the acoustic device using the tool and placing the acoustic device in a cell using the tool. The shaping process can be carried out by inserting a plurality of fingers at the end of the acoustic device. Tool insertion is performed using a tool tip to open the end of the acoustic device into which the tool can be inserted. The fingers are inserted into the acoustic device after the tool has been inserted into the acoustic device. The method may further comprise applying an adhesive to the acoustic device and connecting the acoustic device to the cell. The adhesive is cured by directing radiation from the tool onto the adhesive.
    [0012] According to yet another described modality, a method of making a plurality of acoustic devices adapted to be placed in a cell nucleus is provided. Strips of acoustic material are superimposed and cut into a plurality of individual pieces, each having a profile of one of the acoustic devices. The individual pieces are then joined together along their edges. The tapes can be cut and joined together using a laser. The method may further comprise placing at least one adhesive tape over the overlapping tapes of acoustic material. The laser can be used to cut the adhesive tapes.
    [0013] The characteristics, functions and advantages can be achieved independently in various modalities of the present invention or can be combined in still other modalities in which more details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS
    [0014] The novelties believed to be characteristic of the illustrative modalities are given in the attached claims. The illustrative modalities, however, as well as a preferred mode of use, other of its objectives and advantages, will be better understood by reference to the following detailed description of an illustrative modality of the present invention when taken in conjunction with the accompanying drawings in which: Figure 1 is an illustration of a perspective view of a cell nucleus in septa, portions of the cell wall being highlighted to reveal individual septa.
    [0015] Figure 2 is an illustration of a cross-sectional view of a portion of the internal acoustic lining.
    [0016] Figure 3 is an illustration of a block diagram of a system for producing acoustic structures.
    [0017] Figure 4 is an illustration of a perspective view showing the acoustic and adhesive tapes pulled over a cutting table.
    [0018] Figure 5 is an illustration similar to figure 4, but showing tapes having been pulled down on the cutting table and a laser having cut the tapes in a group of individual septa.
    [0019] Figure 6 is an illustration of a perspective view of an end effector mounted on a robot.
    [0020] Figure 7 is an illustration of an end elevation view of the end effector, in which the folded position of the placement tools is indicated in broken lines.
    [0021] Figure 8 is an illustration of a side elevation view of the end effector shown in figure 7.
    [0022] Figure 9 is an illustration of a perspective view of the end effector positioned to capture a group of individual septa.
    [0023] Figure 10 is an illustration of an enlarged perspective view showing the placement tools in the process of capturing the septa.
    [0024] Figure 11 is an illustration of an end elevation view of the end effector, showing the placement tools in the fully folded position.
    [0025] Figure 12 is an illustration similar to figure 11, but showing a bank of the placement tools having partially rotated in preparation to capture a set of septa.
    [0026] Figure 13 is an illustration similar to figure 11, but showing the other bank of the placement tools having been partially rotated in preparation to capture the other set of septa.
    [0027] Figure 14 is an illustration of a side elevation view showing one of the placement tools ready to capture one of the septa.
    [0028] Figure 15 is an illustration similar to figure 14, but showing the placement tool having been opened and entered the septum.
    [0029] Figure 16 is an illustration similar to figure 15, but showing the formation of fingers on the placement tool having moved to and formed the open end of the septum.
    [0030] Figure 17 is an illustration of an isometric view showing a curved segment of a cell nucleus in which septa must be placed by the end effector.
    [0031] Figure 18 is an illustration of a perspective view showing the end effector having positioned the placement tools above individual cells in the nucleus.
    [0032] Figure 19 is an illustration of an isometric view showing how the visualization system aligns the placement tools in relation to the cells and in which one of the septa is being placed in a cell by one of the placement tools.
    [0033] Figure 20 is an illustration of a perspective view showing the cure of the adhesive by radiant thermal energy.
    [0034] Figure 21 is an illustration of an enlarged perspective view, showing better how the radiant thermal energy is transmitted from the placement tool to the adhesive area.
    [0035] Figure 22 is an illustration of a diagrammatic view showing radiant thermal energy used to connect the acoustic device to the cell nucleus, portions of a cell wall being detached to reveal an adhesive tape.
    [0036] Figure 23 is an illustration of a perspective view of a portion of the cell nucleus shown in Figure 17 after several have been placed and connected in place.
    [0037] Figure 24 is an illustration of a flow chart of an automated method of producing acoustic structures.
    [0038] Figure 25 is an illustration of an aircraft production flowchart and service methodology.
    [0039] Figure 26 is an illustration of an aircraft block diagram. DETAILED DESCRIPTION
    [0040] The described modalities refer to a method and apparatus for automated production of acoustic structures such as a cell acoustic nucleus containing large amounts of acoustic devices. For example, with reference to figure 1, an acoustic structure 30 has a cellular acoustic nucleus 32, sometimes called here an alveolar nucleus, containing a multiplicity of individual cells 42. Each of the cells 42 contains a generally hollow acoustic device 34 for alter the acoustic characteristics of the cell nucleus 32, such as sound attenuation. In the illustrated example, the acoustic device 34 comprises a discrete, cone-shaped septum 34 that is connected to the cell nucleus 32, however other types of acoustic devices 34 can be installed in the cell nucleus 32 using the method and apparatus described below.
    [0041] Referring now to figure 2, the method and apparatus described can be used, for example and without limitation, to divide a cell nucleus 32 of an acoustic structure 30 employed as an acoustic inner lining 30. The acoustic inner lining 30 can be used on various parts of a jet engine to attenuate noise. The acoustic inner lining 30 is a sandwich panel construction largely comprising a honeycomb core 32 sandwiched between inner and outer face sheets 36, 38 respectively. The inner face sheet 36 includes a plurality of perforations 40 in it that allow sound waves, including noise, to pass through the inner face sheet 36 into the cell nucleus 32. The inner face sheet 36 is attached to the top of the nucleus cell 32 by any appropriate process such as adhesive bonding. Similarly, the outer face sheet 38 can be attached to the bottom of the cell nucleus 32 by adhesive bonding.
    [0042] In the illustrated embodiment, each of the inner and outer face sheets 36, 38 may comprise a composite laminate such as a CFRP (carbon fiber reinforced plastic) however, any of these face sheets may comprise other materials. The alveolar nucleus 32 is formed from a multiplicity of individual polygonal cells 42 which are defined by a series of cell walls 44. In the illustrated example, cells 42 are hexagonal, however other cell geometries are possible. The alveolar core 32 is divided into septa by a plurality of individual composite septa 34 which are precisely placed in and connected to the nucleus 32 using the method and apparatus described below. The septa 34 are perforated or can be formed from a porous material such as a mesh that allows a portion of the sound waves to pass through the septa 34, below the cells 42 to the outer face 38.
    [0043] Individual septa 34, which may be collectively called septa 34, have an upper section 46 and a lower section 48. The upper sections 46 of septa 34 have substantially the same cross-sectional shape as cells 42 (hexagonal in the illustrated embodiment) and are bonded by adhesive to the walls of cell 44, thereby fixing the position of septa 34 within cells 42. In the illustrated embodiment, the walls of cell 44 and septa 34 can be formed of a composite cloth (tissue or knitted) such as a PEEK thermoplastic, however other materials are possible.
    [0044] The lower section 48 of the generally hollow septa 34 extends downwards within cells 42 to a desired depth, forming cavities 50 within cells 42 of a pre-selected volume, shape and surface area that obtain acoustic performance desired for a chosen application. For example, the size, shape and surface area of the septa 34 can be selected to form resonant cavities 50 that help to cancel or dampen sound waves / noise passing through the acoustic structure 30 that enter the cell nucleus 32 through the perforations 40 in the sheet. inner face 36.
    [0045] In the illustrated modality, the lower section 48 of the septa 34 is generally conical in shape, however the septa 34 can have other shapes that can be constant or variable by the cell nucleus area 32, allowing the acoustic structure 30 to be tuned in different areas to attenuate different types of noise, such as noise in different frequency ranges. Also, although the upper sections 46 of septa 34 are positioned at the top of cells 42 in the embodiment illustrated, in other embodiments the septa 34 may be positioned lower within cells 42 such that the upper sections 46 are spaced below the top of the cells 42. As noted earlier, septa 34 are merely illustrative of a wide range of acoustic device 34 that can be installed in cell nucleus 32 according to the method described.
    [0046] Attention is now directed to figure 3 which broadly illustrates the functional components of the apparatus 55 for automated production of acoustic structures 30 having a plurality of individual cells 42 containing generally hollow acoustic devices 34 such as septa. The apparatus 55 comprises a material supply system 56, an automatically controlled laser cutter / welder 62, an end effector 60 and a digital controller 80. The material supply system 56 provides a supply of sheets of acoustic material in the form of acoustic material tapes 58 and an adhesive supply in the form of adhesive material tapes 65. Acoustic tapes 58 are cut to the desired shape by individual acoustic devices 34 by laser cutter / welder 62. Adhesive tapes 65 (hereinafter sometimes called "adhesive") are applied to individual septa 34 for use in binding the acoustic devices 34 within the individual cells 42 of the cell nucleus 32. Although the binding adhesive 65 is shown as tapes in the illustrated embodiment, in other embodiments the adhesive 65 it can be in other forms such as a paste adhesive, a liquid adhesive or strips of an adhesive that are applied to the acoustic devices 34 using any of a variety of techniques. The laser cutter / welder 62 is mounted on a manipulator 64 that can comprise a robot (not shown), mobile support (not shown) or similar machine that is digitally controlled by controller 80 and is capable of moving the laser cutter / welder 62 on a desired programmed route. As will be discussed below, the laser cutter / welder 62 acts both as a cutter that cuts sheets of the acoustic material in the desired shapes and as a joining device that joins the edges of the sheets after they have been cut into the desired profile shape.
    [0047] The end effector 60 is mounted on a manipulator 66 which can be the same as, or different from the manipulator 64 used to control the laser cutter / welder 62. In the illustrated example, as will be discussed below, the manipulator 66 comprises a robot having multiple degrees of freedom and capable of moving end effector 60 along multiple axes, under the control of digital controller 80. Digital controller 80 may comprise, for example and without limitation, a PC (personal computer) , a general purpose program computer or a PLC (programmable logic controller). The digital controller 80 may include, or have access to, a set of programmed digital instructions 82 in the form of one or more software programs.
    The end effector 60 includes a machine display system 72, a plurality of acoustic device placement tools 68, a vacuum system 70 and one or more curing devices 78 that may comprise a radiation generator. Each of the acoustic device placement tools 68 is coupled with the vacuum system 70 which functions to retain the acoustic device 34 until it has been placed and connected within a cell 42. The machine's visualization system 72 may include a laser 74 to direct a laser dot (not shown) on cell nucleus 32 and a camera system 76 to view nucleus 32 and detect the laser dot as well as other details of cell nucleus 32 required to precisely align and place devices acoustic 34 in cells 42 of the nucleus. Each of the curing devices 78 is operative to generate radiation which cures the adhesive 65 during the installation process in order to connect the acoustic device 34 to the walls of cell 44 (figure 2) of cell 42 in which it has been installed. The radiation generated by the curing device 78 can be thermal (e.g., infrared), UV (ultraviolet) or other wavelengths suitable for the curing process of adhesive 65 that is chosen for the application.
    [0049] Attention is now directed to figures 4 and 5 which illustrate additional details of the material supply system 56 and a process for producing acoustic devices 34 using laser cutter / welder 62. The material supply system 56 comprises of broadly speaking, two reels 84, 86 of acoustic tapes 58 and two reels 90 of adhesive 65. The tapes of acoustic material 58 are pulled from reels 84, 86 and taken in an overlapping relationship, forming a double layer of acoustic material, before to be pulled through a pair of pinch rollers 93 onto a flat table 95. Table 95 can be a perforated pneumatic table coupled with a vacuum that pulls the double layers of acoustic material and compressed on table 95 in order to eliminate wrinkling and retaining the double layer plates during subsequent processing.
    [0050] Adhesive 65, which may be in the form of tape or other, is pulled out of the reels 90 in a laterally spaced relation and is aligned with the outer edges of the tapes of acoustic material 58, before being pulled through the rollers. tightening 93 to the outer edges of the double layers of the acoustic material tapes 58. The laser cutter / welder 62, operated by the digital controller 80 (figure 3), cuts the double layers of acoustic material into individual stacked pieces having the shape of the acoustic devices 34, arranged in alternating mirrored patterns. Adhesive tape 65 can be cut by laser cutter / welder 62 along with tape 58 of acoustic material. As the laser cut is carried out, the heat produced by the laser cutter / welder 62 welds and joins the cut edges of the two layers together. Although a laser cutter / welder 62 has been described, other techniques for cutting tapes 58 of acoustic material and adhesive 65 into the shape of septa 34 and then sealing the cut edges can be employed. Additionally, as previously mentioned, adhesive 65 can be in forms other than tapes and can be applied to acoustic devices 34 using any of a variety of other techniques.
    [0051] With reference now to figures 6, 7 and 8, the end effector 60 comprises a frame 92 mounted on an arm of a robot 66 which is movable along a track 98. The end effector 60 includes a plurality of placement tools 68 that pick up generally hollow acoustic devices 34 from table 95 (figures 4 and 5) and transport them to a cell nucleus described later where placement tools 68 are used to place and connect acoustic devices 34 on nucleus cells 42.
    [0052] As best seen in figure 7, the laying tools 68 are arranged on two opposite banks 100, 102, each comprising a plurality of laying tools 68 that are aligned and spaced apart at distances "d" corresponding to the spacing between cells 42 of the nucleus. Similarly, banks 100, 102 are spaced from each other by a distance "D" corresponding to a predetermined multiple of the spacing between cells 42 of the nucleus. The placement tools 68 on each of the benches 100, 102 are pivotally mounted on a tree 94 attached by its opposite ends to hangers 96 attached to, and extending downwards from the frame 92.
    [0053] Each of the insertion tools 68 comprises a conical-shaped foot mandrel 104 having vacuum captors 120 which are connected to the vacuum system 70 (figure 3). A spindle 106 connects each of the chucks 104 with a mounting block 108 which, in turn, is pivotally mounted on one of the trees 94, thereby mounting the laying tools 68 for pivoting movement 114 between a pickup position of the acoustic device (broken lines in figure 7) and a position for placing the acoustic device.
    [0054] A shaper 110 is threaded over and linearly displaceable along each of the spindles 106. Each shaper 110 includes a plurality of circumferentially spaced shaping fingers 112 having outer tips that are configured to substantially match the geometry of the shafts. walls of cell 44 (figure 2) of core 32. Conformers 110 are pneumatically actuated via pneumatic lines 116, while vacuum sensors 120 are coupled with vacuum system 70 by vacuum lines 118 to produce a suction force that retains the acoustic devices on the chucks 104. It should be noted here that the placement tools 68 described above are merely illustrative of tools that can be mounted on the end effector 60 and used to "capture and place" the acoustic devices 34 in the cells 42 of the core. The exact configuration and characteristics of the placement tools 68 may vary depending on the application, the size and shape of the acoustic devices 34 and the geometry of the nucleus cells 42. In addition, the number of placement tools 68 that are mounted on end effector 60 may vary with the application. In some applications, a single of the placement tools 68 may be satisfactory and effective for placing the acoustic devices 34 in the cells 42 of the nucleus.
    [0055] Attention is now directed to figures 9-16 which illustrate the operation of the end effector 60 during capture of the acoustic devices 34 from the table 95. The capture sequence involves lateral displacement 122 (figure 9) of the end effector 60 , back and forth through the acoustic material tape 58 that was cut on the individual acoustic devices 34. With the two banks 100, 102 of laying tools 68 in their folded position shown in figure 11, the end effector 60 is lowered to a position that is slightly above the surface of table 95, as best seen in figure 9.
    [0056] Next, as shown in figures 9 and 12, one of the seats 102 is partially pivoted 115 downwards (see figure 12) to align the end of the chucks 104 with the open ends 125 (figure 14) of the acoustic devices 34 of a bank 102 of them, which at this stage, are in a flat, collapsed state. Then, the end effector 60 is laterally displaced 122 (figure 9), causing the mandrel 104 to enter the open end 125 and then open the acoustic device 34, as shown in figures 10 and 15. The vacuum sensor 120 is then actuated , causing the hollow acoustic device 34 to be sucked in and pulled against the mandrel 104, thereby retaining the acoustic device 34 against the tool 68.
    [0057] Next, as shown in figure 16, the shaper 110 is moved 130 to the open end 125 of the acoustic device 34, causing the fingers 112 to conform the periphery 132 of the acoustic device 34 to substantially match the cross-sectional shape of cells 42 of the nucleus which, in the illustrated format, is hexagonal. After a set of acoustic devices 34 has been picked up by a bench 102 of the placement tools 68, the bench 102 is rotated to the transport position shown in figure 13 and the other bench 100 is rotated to its pickup position, then that the placement tools 68 on the bench 100 proceed to pick up the remaining set of acoustic devices 34 from the table 95.
    [0058] Referring now to figures 17-19, with a complete set of acoustic devices 34 having been picked up by end effector 60, robot 66 (figure 17) transports end effector 60 to the vicinity of core 32, which , in the illustrated example it is curved. One or more laser guide points are directed from the end effector 60 onto the cell nucleus 32 and a camera system 76 (figure 3) visualizes the surface of the cell nucleus 32 and detects laser points. The visualization system 72 cooperates with the digital controller 80 to assist 134 (figure 19) the position of the end effector 60 such that the placement tools 68 are precisely aligned with the center lines of a group of cells 42 of the core.
    [0059] With the placement tools 68 having been aligned with the cells 42 of the nucleus, the end effector 60 moves the placement tools 68 to the nucleus 32, thereby placing and inserting the acoustic devices 34 in a chosen set of cells 42 of the core. The acoustic devices 34 are inserted at a desired, pre-programmed depth into cells 42 of the nucleus, which in the illustrated example results in the top of the acoustic devices 34 being located at the top of cells 42 of the nucleus (see figures 1 and 2).
    [0060] Attention is now directed to figures 20-22 which illustrate the process for adhesively attaching the acoustic devices 34 to the cell nucleus 32 after the end effector 60 has placed a set of the acoustic devices 34 inside cells 42. An curing 78 surrounds each of the spindles 106 and is operative to direct thermal radiation 138, or other forms of radiation, to the top of the acoustic devices 34. Thermal radiation 138 heats the adhesive 65 surrounding the acoustic device 34 to the curing temperature of the adhesive, thereby connecting the acoustic device 34 to the walls of the cell 44.
    [0061] In one embodiment, each of the curing devices 78 can comprise a laser diode or a ring of laser diodes, however other types of devices that cure adhesive 65 can be employed. Also, although the curing devices 78 are mounted on the placement tools 68 in the illustrated embodiment, it may be possible to mount the curing devices 78 in other locations on the end effector 60. Depending on the type of adhesive 65 that is employed, it can be it may be possible to achieve curing of the adhesive using other types of radiation, such as ultrasonic energy, UV or otherwise.
    [0062] After the acoustic devices 34 have been connected within the cells 42 of the nucleus, the vacuum that holds the acoustic devices 34 on the placement tools 68 is removed, thereby releasing the acoustic devices 34 from the placement tools 68. Once Once the vacuum is removed, the end effector 60 moves upwards away from the cell nucleus 32, removing the placement tools 68 from the acoustic devices 34. In some applications, a slight positive pressure can be applied through the vacuum sensors 120 (see figure 14) to ensure that there is a full release of the acoustic devices 34 from the placement tools 68. Figure 23 illustrates a cell nucleus 32 in which a set of the acoustic devices 34 has been placed and connected within the cells 42 of the nucleus.
    [0063] Figure 24 illustrates the overall steps of a method of connecting a plurality of acoustic devices 34 in a cell nucleus 32, using modalities of the apparatus described above. Beginning in 140, a plurality of acoustic devices 34 are manufactured, using a laser 62 or other device to perimetrally cut and weld each of the devices 34. In 142 groups of the acoustic devices 34 are captured using placement tools 68 having vacuum captors 120 which hold the acoustic devices 34 on mandrels 104 as part of the placement tools 68.
    [0064] In 144 the groups of the acoustic devices 34 that were captured, are then placed respectively in cells 42 of the core 32. A visualization system 72 of the machine together with an automatically controlled end effector 60 is used to precisely align the devices acoustic 34 in cells 42 of the nucleus. At 146, the acoustic devices 34 are adhesively bonded to the core 32 using thermal, UV or otherwise 138 radiation to activate a bonding adhesive 65 applied to the acoustic devices 34.
    [0065] Modalities of the invention can find use in a variety of potential applications, particularly in the transport industry, including for example, aerospace, marine, automotive and other applications where acoustic treatments, such as acoustic internal coatings, can be used. Thus, with reference now to figures 25 and 26, modalities of the invention can be used in the context of an aircraft manufacturing and maintenance method 148 as shown in figure 25 and an aircraft 150 as shown in figure 26. Aircraft applications of the described modalities they may include, for example, without limitation, internal acoustic coatings for sound attenuation in jet engines. During pre-production, the exemplary method 148 may include specification and design 152 of aircraft 150 and material acquisition 154. During production, manufacturing of components and subassemblies 156 and system integration 158 of aircraft 150 takes place. Thereafter, aircraft 150 can pass through certification and delivery 160 in order to be put into service 162. While in service by a customer, aircraft 150 is scheduled for routine maintenance and service 164, which may also include modification, reconfiguration , remodeling and others.
    [0066] Each of the 148 method processes can be performed or conducted by a system integrator, 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 large system subcontractors; a third party 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 others.
    [0067] As shown in figure 26, the aircraft 150 produced by the exemplary method 148 may include a fuselage 166 with a plurality of systems 168 and an interior 170. Examples of high-level systems 168 include one or more among a 172 propulsion system, an electrical system 174, a hydraulic system 176 and an environmental system 178. 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 naval and automotive industries.
    [0068] Systems and methods embodied herein can be employed during any one or more of the stages of the production and service method 148. For example, components or subassemblies corresponding to production processes 156 and 158 can be manufactured or manufactured in a similar manner to those components or subassemblies produced while the aircraft 150 is in service. Also, one or more apparatus modalities, method modalities, or a combination thereof can be used during production stages 156 and 158, for example, substantially speeding up assembly or reducing the cost of an aircraft 150. Similarly, one or more of the apparatus modalities, method modalities or a combination of them can be used while the aircraft 150 is in service, for example and without limitation, in maintenance and service 164.
    [0069] As used here, the phrase “at least one of”, when used with a list of items, means that different combinations of one or more of the items listed can be used and only one of each item in the list may be needed. For example, “at least one of item A, item B and item C” can include, without limitation, item A, item A and item B, or item B. This example can also include item A, item B and item C or item B and item C. The item can be an object, thing or a particular category. In other words, at least one of means that any combination of items and number of items can be used from the list, but not all items on the list are required.
    [0070] In addition, the invention comprises modalities according to the following clauses: Clause 1. Apparatus for producing an acoustic structure having a nucleus with a plurality of cells, comprising: a manipulator; an end effector mounted on the manipulator, including a plurality of acoustic device placement tools each capable of placing an acoustic device in one of the nucleus cells; and a digital controller including a set of digital instructions to control the movement of the manipulator and operation of the end effector. Clause 2. The apparatus of clause 1, in which the acoustic device placement tools are arranged in a first and a second opposite seat. Clause 3. The apparatus of clause 1, in which each of the acoustic device placement tools is mounted on the end effector for pivoting movement between an acoustic positioning device and an acoustic positioning device. Clause 4. The apparatus of clause 1, in which each of the acoustic device placement tools includes a mandrel capable of being inserted into the acoustic device. Clause 5. The apparatus of clause 4, in which each of the acoustic device placement tools includes a vacuum sensor to retain an acoustic device over the mandrel. Clause 6. The apparatus of clause 4, wherein each of the acoustic device placement tools further includes a plurality of fingers movable to an end of the acoustic device to conform the end of the acoustic device to conjugate with the cells. Clause 7. The apparatus of clause 1 further comprises: a visualization system to guide the end effector and align each of the acoustic device placement tools with one of the core cells. Clause 8. The apparatus of clause 7, in which the visualization system includes: a laser mounted on the end effector to direct a laser point on the core; and, a camera mounted on the end effector to view the cells of the nucleus. Clause 9. The apparatus of clause 1 further comprises: a material supply system for supplying overlapping tapes of acoustic material and tapes of adhesive material that overlap and adhere to the tapes of acoustic material. Clause 10. The apparatus of clause 9, further comprises: a laser coupled with the digital controller to cut the acoustic tapes in a format of the acoustic devices. Clause 11. The apparatus of clause 9 further comprises a device coupled with each of the acoustic device placement tools for curing the adhesive tapes. Clause 12. The apparatus of clause 11, in which the device comprises a thermal radiation generator capable of directing thermal radiation onto the adhesive tape. Clause 13. Apparatus for automated production of an acoustic core having a plurality of cells, comprising: a material supply system for supplying acoustic material tapes; a laser to convert the tapes into a plurality of acoustic devices; an end effector to capture the acoustic devices and place the acoustic devices in the cells; and, a controller coupled with the laser and the end effector. Clause 14. The apparatus of clause 13, in which the material supply system includes two reels of acoustic tapes capable of being pulled out of the reels in an overlapping relationship with each other. Clause 15. The apparatus of clause 13, in which the material supply system also includes two spools of adhesive tapes capable of being pulled out from the spools in a laterally spaced relation to each other and overlapping the tapes of acoustic material. Clause 16. The apparatus of clause 13, in which the controller is able to control the operation of the laser and includes a set of programmed instructions that direct the laser to cut the acoustic devices from the strips of acoustic material. Clause 17. The apparatus of clause 13, wherein the end effector includes a plurality of acoustic device placement tools each capable of placing an acoustic device in one of the nucleus cells. Clause 18. The apparatus of clause 17, in which each of the acoustic device placement tools includes: a mandrel insertable in one of the acoustic devices, and a vacuum system coupled with the mandrel and capable of generating a vacuum within the acoustic device to retain the acoustic device over the mandrel. Clause 19. The apparatus of clause 17, wherein each of the acoustic device placement tools includes a shaper and displaceable at one end of the acoustic device to conform the end of the acoustic device to conjugate with the cells. Clause 20. The apparatus of clause 17 further comprises: a visualization system coupled with the controller to align the placement tools of the acoustic device with each of the cells of the nucleus. Clause 21. Apparatus for installing an acoustic device generally hollow in a cell of a cell nucleus, comprising: a tool capable of being inserted into the acoustic device; a vacuum sensor on the tool capable of holding the acoustic device against the tool; and a shaper on the tool for shaping an end of the acoustic device. Clause 22. The apparatus of clause 21, in which: the tool is elongated and tapered along its length, and the shaper includes sliding fingers on the tool and for the acoustic device. Clause 23. The apparatus of clause 22, in which the fingers are circumferentially spaced around each other around the tool. Clause 24. The apparatus of clause 22, wherein each of the fingers has an outer tip shaped to form an end of the acoustic device to substantially match a shape of the cell. Clause 25. The apparatus of clause 22 further comprises: a radiation generator coupled with the tool and capable of directing radiation to the acoustic device during installation of the acoustic device in the cell. Clause 26. Apparatus for manufacturing a plurality of acoustic devices adapted to be installed in a cell nucleus, comprising: a supply of adhesive to connect each of the acoustic devices to the nucleus; a supply of sheets of acoustic material; a cutter to cut the sheets of acoustic material into a desired shape; and, a joining device for joining the sheets of acoustic material together. Clause 27. The apparatus of clause 26, in which the adhesive supply includes a tape of adhesive material capable of being pulled over the sheets of acoustic material. Clause 28. The apparatus of clause 26, in which the supply of sheets of acoustic material includes first and second strips of acoustic material aligned to be pulled in relation to each other overlap. Clause 29. The apparatus of clause 26, in which the cutter is an automatically controlled laser. Clause 30. The apparatus of clause 26, in which the joining device is an automatically controlled laser. Clause 31. A method of automated production of an acoustic core having a plurality of cells, comprising: manufacturing a plurality of acoustic devices; capture groups of acoustic devices; placing the groups of the acoustic devices respectively in cells of the nucleus; and connect the acoustic devices to the core. Clause 32. The method of clause 31, in which the manufacture of the plurality of acoustic devices includes: superimposing tapes of acoustic material, and laser cutting the tapes in a shape of the acoustic devices and welding together the edges of the tape surrounding at least a portion of each of the acoustic devices. Clause 33. The method of clause 31, in which capturing groups of acoustic devices includes: inserting a plurality of chucks respectively in the acoustic devices, and retaining the acoustic devices on the chucks using suction force. Clause 34. The method of clause 31, in which placing the groups of acoustic devices respectively in the nucleus cells includes using a visualization system to align the acoustic devices with the cells. Clause 35. The method of clause 31, in which connecting the acoustic devices to the core includes directing thermal radiation to the acoustic devices after the acoustic devices have been placed in the core. Clause 36. A method for installing an acoustic device usually hollow in a cell of a cell nucleus, comprising: inserting a tool into the acoustic device; using a vacuum to retain the acoustic device on the tool; shaping one end of the acoustic device to match a shape of the cell; capture the acoustic device using the tool; and place the acoustic device in a cell using the tool. Clause 37. The method of clause 36, in which inserting the tool into the acoustic device includes using a tip of the tool to spread the end of the acoustic device into which the tool can be inserted. Clause 38. The method of clause 36, in which forming one end of the acoustic device includes inserting a plurality of fingers at the end of the acoustic device. Clause 39. The method of clause 38, in which inserting a plurality of fingers is carried out by sliding fingers over the tool in the acoustic device after the tool has been inserted into the acoustic device. Clause 40. The method of clause 36 further comprises: applying an adhesive to the acoustic device, and connecting the acoustic device to the cell, including curing the adhesive by directing radiation from the tool onto the adhesive. Clause 41. A method of fabricating a plurality of acoustic devices adapted to be placed in a cell nucleus, comprising: superimposing strips of acoustic material; cutting the overlapping tapes into a plurality of individual pieces of acoustic material each having a profile of one of the acoustic devices; and join the individual pieces along their edges. Clause 42. The method of clause 41, in which cutting the overlapping tapes is performed by a laser. Clause 43. The method of clause 41, in which joining the longest individual parts includes laser welding the individual parts together. Clause 44. The method of clause 41 further comprises: placing at least one adhesive tape over the overlapping tapes of acoustic material, and where cutting the overlapping tapes includes cutting the adhesive tapes.
    [0071] A description of the different modalities of the tool has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the modalities in the manner described. Many modifications and variations will be apparent to those of ordinary skill in the art. Other different illustrative modalities can provide different advantages compared to other illustrative modalities. The modality or modalities selected are chosen and described in order to better explain the principles of the modalities, their practical application and to enable others of common skill in the technique to understand the description for various modalities with various modifications as they are suitable for use. particular contemplated.
    权利要求:
    Claims (26)
    [0001]
    1. Apparatus for producing an acoustic structure (30) having a nucleus (32) with a plurality of cells (42), characterized by the fact that it comprises: a manipulator (66); an end effector (60) mounted on said manipulator (66), including a plurality of acoustic device placement tools (68) (34), each capable of placing an acoustic device (34) in one of the cells (42) the core (32), where the tool (68) is elongated and tapered along its length; a digital controller (80) including a set of digital instructions (62) to control movement of the manipulator (66) and operation of the end effector (60); and a material supply system (56) for supplying overlapping tapes of acoustic material (58) and tapes (58) of adhesive material (65) that overlap and adhere to the tapes (65) of acoustic material (58).
    [0002]
    2. Apparatus according to claim 1, characterized by the fact that the placement tools (68) of the acoustic device (34) are arranged in a first opposite seat and a second opposite seat (100, 102).
    [0003]
    3. Apparatus according to claim 1, characterized by the fact that each of the acoustic device placement tools (68) is mounted on the end effector (60) for pivoting movement between an acoustic device capture position (34) and an acoustic device placement position (34).
    [0004]
    Apparatus according to claim 1, characterized by the fact that each of the acoustic device placement tools (68) includes a mandrel (104) capable of being inserted in said acoustic device (34).
    [0005]
    Apparatus according to claim 4, characterized in that each of the acoustic device placement tools (68) includes a vacuum sensor to hold an acoustic device (34) on the mandrel (104).
    [0006]
    Apparatus according to claim 4, characterized in that each of the acoustic device placement tools (68) further includes a plurality of fingers movable to one end of the acoustic device (34) to conform the end that acoustic device (34) to conjugate with the cells (42).
    [0007]
    Apparatus according to claim 1, characterized by the fact that it further comprises: a visualization system to guide the end effector (60) and align each of those acoustic device placement tools (68) with a of the cells (42) of the nucleus (32).
    [0008]
    Apparatus according to claim 7, characterized in that the visualization system includes: a laser (74) mounted on the end effector (60) to direct a laser point (74) on the core (32) ; and, a camera (76) mounted on the end effector (60) to view the cells (42) of the nucleus (32).
    [0009]
    9. Apparatus according to claim 1, characterized by the fact that it further comprises: a laser (74) coupled with the digital controller (80) to cut the acoustic tapes (58) in a format of the acoustic devices (34).
    [0010]
    Apparatus according to claim 1, characterized in that it further comprises: a device coupled with each of those placement tools (68) of an acoustic device (34) for curing (78) the adhesive material tapes (65) .
    [0011]
    Apparatus according to claim 10, characterized in that the curing device (78) comprises a thermal radiation generator capable of directing thermal radiation on the adhesive tape (65).
    [0012]
    12. Apparatus for automated production of an acoustic core (32) having a plurality of cells (42), characterized by comprising: a material supply system (56) for supplying acoustic material tapes (58); a laser (62) for converting the tapes (58) into a plurality of acoustic devices (34); an end effector (60) to pick up those acoustic devices (34) and place the acoustic devices (34) in the cells (42); and, a controller (80) coupled with the laser (62) and the end effector (60).
    [0013]
    13. Apparatus according to claim 12, characterized in that the material supply system (56) includes two reels (84, 86) of acoustic tapes (58) capable of being pulled out from the reels in relation to overlap with each other.
    [0014]
    Apparatus according to claim 12, characterized by the fact that said material supply system (56) further includes two spools (90) of adhesive tapes (65) capable of being pulled out from the spools in relation to laterally spaced from each other and overlapping the strips of acoustic material (58).
    [0015]
    Apparatus according to claim 12, characterized by the fact that the controller (80) is capable of controlling laser operation (62) and includes a set of programmed instructions that direct the laser (62) to cut out the acoustic devices ( 34) of acoustic material tapes (58).
    [0016]
    Apparatus according to claim 12, characterized in that the end effector (60) includes a plurality of acoustic device placement tools (68), each capable of placing an acoustic device (34) in one of the cells (42) of the acoustic nucleus (32).
    [0017]
    17. Apparatus according to claim 16, characterized in that each of these acoustic device placement tools (68) includes: a mandrel (104) that can be inserted into one of the acoustic devices (34), and a system vacuum (70) coupled with the mandrel (104) and capable of generating a vacuum within the acoustic device (34) to retain such an acoustic device (34) on the mandrel (104).
    [0018]
    Apparatus according to claim 16, characterized in that each of these acoustic device placement tools (68) includes a former (110) and is movable at one end of the acoustic device (34) to conform that end of the acoustic device (34) to conjugate with the cells (42).
    [0019]
    19. Apparatus according to claim 16, characterized in that it additionally comprises: a visualization system coupled with such a controller to align the placement tools (68) of an acoustic device (34) with each of the cells (42) of the acoustic core (32).
    [0020]
    20. Apparatus for installing an acoustic device (34) in a cell (42) of a cell nucleus (32), wherein said acoustic device (34) is generally hollow, the apparatus being characterized by comprising: a tool (68) able to be inserted in the acoustic device (34), in which the tool (68) is elongated and tapered along its length; a vacuum sensor (120) on the tool (68) capable of holding the acoustic device (34) against the tool (68); and a shaper (110) on the tool (68) for shaping an end of the acoustic device (34), wherein the shaper (110) includes fingers (112) slidable by the tool (68) and for the acoustic device (34).
    [0021]
    21. Apparatus according to claim 20, characterized in that the fingers (112) are circumferentially spaced around each other around the tool (68).
    [0022]
    22. Apparatus according to claim 20, characterized in that each of the fingers (112) has an external tip shaped to form an end of the acoustic device (34) to substantially conjugate with a shape of the cell (42 ).
    [0023]
    23. Apparatus according to claim 20, characterized by the fact that it additionally comprises: a radiation generator coupled with the tool (68) and capable of directing radiation to the acoustic device (34) during installation of said acoustic device (34) in the cell (42).
    [0024]
    24. Method of automated production of an acoustic core (32) having a plurality of cells (42), characterized by comprising: manufacturing a plurality of acoustic devices (34); capture groups of acoustic devices (34); placing the groups of such acoustic devices (34) in cells (42) of the acoustic nucleus (32), respectively; and connecting the acoustic devices (34) to the acoustic core (32).
    [0025]
    25. Method for installing an acoustic device (34) in a cell (42) of a cell nucleus (32), wherein said acoustic device (34) is generally hollow, the method being characterized by comprising: inserting a tool (68 ) on the acoustic device (34), using a vacuum to retain the acoustic device (34) on the tool (68); shaping one end of the acoustic device (34) to match a shape of the cell (42); capture the acoustic device (34) using the tool (68); and placing the acoustic device (34) in a cell (42) using the tool (68).
    [0026]
    26. Method of making a plurality of acoustic devices (34), adapted to be placed in a cell nucleus (32), characterized by comprising: superimposing strips of acoustic material (58); cutting the overlapping tapes into a plurality of individual pieces of acoustic material, each having a profile of one of the acoustic devices (34); and join the individual pieces along their edges.
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    同族专利:
    公开号 | 公开日
    CN105280176B|2021-01-12|
    US20170303058A1|2017-10-19|
    US10327084B2|2019-06-18|
    BR102015014080A2|2016-12-20|
    JP6556517B2|2019-08-07|
    EP2960023A1|2015-12-30|
    CN105280176A|2016-01-27|
    US20170303059A1|2017-10-19|
    US10542363B2|2020-01-21|
    JP2016007699A|2016-01-18|
    US9693166B2|2017-06-27|
    US20150373470A1|2015-12-24|
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    法律状态:
    2016-12-20| B03A| Publication of an application: publication of a patent application or of a certificate of addition of invention|
    2018-07-03| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2018-07-24| B11A| Dismissal acc. art.33 of ipl - examination not requested within 36 months of filing|
    2018-12-26| B04C| Request for examination: reinstatement - article 33, solely paragraph, of industrial property law|
    2019-12-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-12-15| B09A| Decision: intention to grant|
    2020-12-29| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 15/06/2015, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/313613|2014-06-24|
    US14/313,613|US9693166B2|2014-06-24|2014-06-24|Automated production of acoustic structures|
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