CN101492098B - 模块化复合材料的制造方法 - Google Patents

模块化复合材料的制造方法 Download PDF

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CN101492098B
CN101492098B CN200810191062.XA CN200810191062A CN101492098B CN 101492098 B CN101492098 B CN 101492098B CN 200810191062 A CN200810191062 A CN 200810191062A CN 101492098 B CN101492098 B CN 101492098B
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module
composite
composite module
lay
manufacture
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CN101492098A (zh
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约瑟夫·D·布伦南
达雷尔·D·琼斯
柯蒂斯·S·威尔登
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Boeing Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
    • B29C31/08—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/10—Manufacturing or assembling aircraft, e.g. jigs therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/1282—Stepped joint cross-sections comprising at least one overlap joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/128—Stepped joint cross-sections
    • B29C66/1286—Stepped joint cross-sections comprising at least one bevelled joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4326—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making hollow articles or hollow-preforms, e.g. half-shells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/435—Making large sheets by joining smaller ones or strips together
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B29L2031/3082—Fuselages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C2001/0054—Fuselage structures substantially made from particular materials
    • B64C2001/0072—Fuselage structures substantially made from particular materials from composite materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/40—Weight reduction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

一种模块化复合材料制造方法。本发明的一个说明性的实施方式包括提供多个复合模块；检查所述复合模块；提供固化工具；以及铺放所述复合模块于固化工具之上。

Description

模块化复合材料的制造方法
技术领域
本说明书大体涉及生产飞机。更具体地，本发明涉及利用复合模块来加工组件和构件的制造方法和装置。
背景技术
现今的商业飞机的一些组件，比如说飞机机身蒙皮，例如可以使用先进的纤维填筑(AFP)机器来加工。在飞机加工工序中使用AFP机器的基准工序在购买许多AFP机器、工具、工厂车间和人事上可能需要很高的投资。在当前的AFP安装率下(例如大约15lbs/hr)，大量的AFP机器可能被需求来铺放大量的材料，所述大量的材料被需求来支撑商业飞机的可接受的生产率。
因此，需要一种能够具有相对较高的速率能力和较低的投资要求并且对于实施可以不需要技巧娴熟的操作者和程序员的制造方法。
发明内容
本发明一般涉及复合材料制造方法。该方法的一个说明性的实施方式包括提供多个复合模块；检查所述复合模块；提供固化工具；以及铺放所述复合模块于固化工具之上。
本方法提供很高的生产率并且仅仅要求较低的投资。另外，该制造方法对于执行可以不需要技术娴熟的操作者和程序员。
在上述方法中，所述固化工具包括外模生产线工具。
在上述方法中，其中所述固化工具包括内模生产线工具。
一种由上述方法加工的飞机。
一种制造复合结构的方法，该方法包括：
提供工具；
提供多个模块；以及
铺放所述模块于工具之上，因此使得：模块中的每一个相邻于模块中的至少另外一个；以及
相邻的模块被结合在一起从而构成复合结构。
在上述方法中，所述铺放步骤包括基本上同时铺放多于一个的模块于工具之上。
在上述方法中，所述铺放步骤包括按照顺序方式铺放所述模块于工具之上，该方法进一步包括：
在后续模块正在铺放于工具上的同时，在已经铺放在工具上的其中一个模块上执行铺放后程序。
在上述方法中，所述执行步骤包括检查所述的已经被铺放于工具上的其中一个模块。
在上述方法中，所述执行步骤包括处理被形成于邻近的模块之间的连接点。
在上述方法中，进一步包括固化复合结构。
一种用于加工复合结构的方法，该方法包括：
准备用于铺放在工具之上的模块；以及
铺放已经按照所述准备步骤准备好的模块于工具之上；
所述准备和铺放步骤基本上同时被实施。
在上述方法中，铺放步骤包括铺放多个模块于工具之上，这样至少两个模块基本上同时可铺放于工具之上。
在上述方法中，铺放步骤包括按照顺序的方式铺放多个模块于固化工具之上，该方法进一步包括：
在后续模块正在铺放于工具上的同时，在已经铺放在工具上的其中一个模块上执行铺放后程序，所述铺放后程序包括检查程序；
其中所述执行步骤和所述铺放后续模块的步骤可以基本上同时被执行。
在上述方法中，所述执行步骤包括处理被形成于邻近铺放的模块之间的连接点。
一种利用多个预加工的模块来制造复合结构的方法，该方法包括：
准备其中一个所述模块用于铺放；
铺放准备好的其中一个模块；以及
在其中一个铺放好的模块上实施铺放后程序；
其中所述准备、铺放以及实施铺放后程序的步骤可以基本上同时被执行。
在上述方法中，进一步包括下列步骤：
铺放多个模块，从而至少两个模块被基本上同时或者按照顺序的方式铺放；以及
在所述多个模块中的至少一个上执行检查程序，在后续模块正在铺放于工具上的同时，在已经铺放在工具上的其中一个模块上执行铺放后程序，其中所述执行步骤所述铺放后续模块的步骤是在基本上相同的时间被执行。
附图简述
图1是制造系统的示意性顶视图，该制造系统适于模块化复合机身蒙皮制造方法的说明性实施方式的实施；
图2是制造系统的透视图，该制造系统适于模块化复合机身蒙皮制造方法的说明性实施方式的实施。
图3是SADL(半自动加倍定位器)机器、拾取和铺放机器以及固化工具的端视图；
图4是流程图，概述了模块化复合机身蒙皮制造方法的说明性实施方式；
图5是飞机制造和服役方法的流程图；
图6是飞机的方框图；
图7是阐释了用于制造复合结构的实施方式的流程图；
图8阐释了另外的用于加工复合结构的实施方式；
图9相邻铺放的复合模块的横截面视图。
具体实施方式
开头先参考附图中的图1-3，一种适于实施模块复合材料制造方法的说明性的实施方式的制造系统一般由附图标记1来指代。该制造系统1被显示在图1的顶视图以及图2的透视图中。模块复合材料制造方法可以使用简单的、合适尺寸的装备从而使得复合材料的建造按照并行的程序而不是串行地进行，作为复合飞机机身或其它部件的加工的一部分。对于飞机机身蒙皮模块或者其它部件的自动分层使用并行程序方法可以显著减少加工单个部件所需持续的时间。这可以减少加工复合飞机机身蒙皮或其它部件所需要的投资、工厂车间以及辅助人员。另外，该方法可以被用于平层铺放复合部件例如但不局限于比方说飞机机身蒙皮的加工，或者起伏铺放复合部件例如但不局限于比方说飞机机翼蒙皮和安定面的加工。该方法可以被用于加工面板、四分之一机身部分、一半机身部分、多于一半机身部分或者全部机身筒体部分。
如在图1和图2中所示，制造系统1可以包括一个或者多个平带铺放机器(FTLMs)2，方便了平层铺放复合部件例如但不局限于比方说飞机机身蒙皮的加工。另外地或者替换地，制造系统1可以包括一个或者多个起伏状铺放机器(CTLMs)(未示出)，方便了起伏铺放复合部件例如但不局限于比方说飞机机翼蒙皮、机头蒙皮和/或尾部蒙皮的加工。FTLM和CTLM可以具有一种所属领域普通技术人员所公知的设计。尽管对于FTLM2的示例性结构和操作方法将在下面被描述，但是应该承认和理解的是相同的操作方法可以针对一个或者多个CTLMs使用，该一个或者多个CTLMs可以附加于或者代替FTLMs2。
每个FTLM2可以包括一对一般细长的、平行的、间隔开的框架导轨3。车架框架4可以跨越并且被用作双向横向往返移动框架导轨3。车架框架4可以包括一对一般细长的、平行的、间隔开的车架框架元件5。车架框架元件5可以被一般地垂至于框架导轨3而定向。
切割车架6可以被用于双向横向往返移动车架框架4的车架框架元件5。车架马达(未示出)可以结合于切割车架6来方便于切割车架6在车架框架4上的运动。切割设备7可以被提供在切割车架6上。虽然为所属领域普通技术人员所公知的并且适合于实现该目的的可选择的切割工具可以被使用，但在一些实施方式中，切割设备7可以是超声波刮刀。
传输平台旋转轨道10被提供在框架导轨3中间并且位于车架框架4下面，其可以是圆形的或者环形的。传输平台14可以被可移除地提供在传输平台旋转轨道10上。传输平台14可以具有一般地正方形的形状。传输平台14的拐角部分14a可以滑动地或者旋转地接合传输平台旋转轨道10，根据所属领域普通技术人员的知识，例如但不局限于比方说通过滚轮(未示出)来实现。如将在下面被描述的，承载片16可以被铺放在传输平台14上。复合模块18可以被铺放在承载片16上。传输平台14可以在传输平台旋转轨道10上旋转，车架框架4可以沿着框架导轨3而移动，并且切割车架6可以沿着车架框架4的车架框架元件5而移动，从而方便了通过操作切割设备7沿着所选择的轴线或坐标轴的而切割复合模块18。
如在图1-3中所示的，制造系统1可以进一步包括SADL(半自动加倍(doubler)定向器)机器22。该SADL机器22可以包括支座23，该支座23能够通过多个支座轮24而移动。模块成形平台25可以被提供在支座23上。该模块成形平台25可以被用来接收和支撑承载片16，在所述承载片16上铺放有复合模块18，用于下面将被描述的目的。
如在图1-3中所进一步显示的，制造系统1可以进一步包括拾取和安置机器30。如在图1和图2中所示的，该拾取和安置机器30可以坐落于邻近SADL机器22。如在图1中所进一步显示的，在一些实施方式中，SADL机器22可以被提供在或者一般邻近于拾取和安置机器30的各个端部。该拾取和安置机器30可以包括台架31，所述台架31具有一对一般细长形的、平行的、间隔开的导轨32。台架31的所述导轨32的每一个可以被多个间隔开的轨座33所支撑，如图3所示。至少一个铺放头机构托架36可以跨越并且可滑动地接合台架31的所述导轨32。每一个铺放头机构托架36可以在导轨32上双向横向移动，如在图1中通过双向箭头8所指示。车架马达(未示出)可以接合每一个铺放头机构托架36从而方便于铺放头机构托架36在导轨32上移动。
如在图2和图3中所示的，模块铺放头机构40可以从每一个铺放头机构托架36悬垂。所述模块铺放头机构40可以包括主动轴41和一般弯曲的或者弧形的模块接合元件42。模块铺放头机构40的所述主动轴41可以被附接于铺放头机构托架36，通过任何所属领域普通技术人员所熟知的合适的技术手段。在一些实施方式中，至少一个头机构安装法兰37从铺放头机构托架36处延伸。至少一个模块附接支架44从主动轴41处延伸。该模块附接支架44可以经由头机构紧固元件38而被连接于至少一个头机构安装法兰37。
如进一步在图2和图3中所示的，模块铺放头机构40的模块接合元件42可以包括一般凸形模块成形表面43。检查扫描系统4b的扫描仪49可以被用于横穿模块接合元件42的模块成形表面43。根据所属领域普通技术人员对于实现此目的的知识，所述扫描仪49可以被附接于模块接合元件42。在一些实施方式中，一般细长形的、弯曲的扫描仪槽缝47可以被提供在模块接合元件42中，一般邻近于并且沿着模块成形表面43。扫描仪支架48可以接合扫描仪槽缝47，从而用于在扫描仪槽缝47内横向移动。扫描仪49可以被提供在扫描仪支架48上。扫描仪马达(未示出)可以接合扫描仪支架48从而便于扫描仪支架48在扫描仪槽缝47中可选择地移动，以及扫描仪49沿着并且邻近于模块接合元件42的模块成形表面43移动。检查分析和控制系统(未示出)可以被连接于扫描仪马达(未示出)和扫描仪49从而便于扫描仪49的扫描运动，以及读取和分析从扫描仪49上所接收到的图像。
制造系统1可以进一步包括固化工具、芯棒或者模54。该固化工具54可以是例如但不局限于OML(外模生产线)或者IML(内模生产线)固化工具。如在图1、2、3中所示的，固化工具54可以坐落于一般邻近于SADL机器22并且位于拾取和安置机器30的导轨32之间。如在图3中所显示的，在一些实施方式中，固化工具54可以包括工具底部55和一般平行的、间隔开的工具侧面56，所述侧面56从工具底部55延伸。一般弯曲的或者半圆形模块铺放表面57可以被提供在工具底部55和工具侧面56中，并且可以沿着固化工具54的长度方向延伸。但是，应该承认和理解的是，固化工具54(例如，比方说在IML固化工具的情况中)不是必须具有完全圆柱形或者半圆柱形横截面，如关于固化工具54的模块铺放表面57而示。在希望将所述制造方法应用于例如但不局限于四分之一面板的情况下，可以使用同时具有OML和IML构形的固化工具54。此外，该固化工具54可以被构造为机翼或者安定面模、工具、固化工具或者任何构形，这取决于将要加工的部件。
在模块化的复合材料制造方法的典型实施方式中，该方法可以利用多个复合模块18加工飞机机身蒙皮60(图1)。取决于应用和将被加工的部件，每个模块18可以包括单向碳纤维预浸渍体；碳纤维预浸渍体织物；玻璃纤维；[聚芳醚醚酮(p-phenyleneterephtalamide)；或其它材料。每个模块18可以具有至少一个板层。承载片16，其上可以被铺放复合模块18，可以首先铺放在传输平台14上。该传输平台14可以铺放在环状的FTLM2传输平台旋转轨道10上。切割车架6上的切割设备7可以操作来修整或者切割复合模块18成为期望的尺寸和形状。在修整、切割或者调整期间，通过切割车架6沿着车架框架4的车架框架元件5的运动；车架框架4沿着框架导轨3的运动；和/或传输平台14在传输平台旋转轨道10上的旋转，复合模块18可以定位在相对于切割设备7所选择的方位上。每个FTLM2利用静修整技术可以便于复合模块18的高速调节，所述复合模块18将形成飞机机身蒙皮60。
在对于复合模块18进行修整或者切割之后，传输平台14可以被从传输平台旋转轨道10上移除，在所述传输平台14铺放有承载片16和被修整或切割的复合模块18。传输平台14可以被从FTLM2输送至SADL机器22中的一个。传输平台14从传输平台旋转轨道10上的移除和/或传输平台14的输送可以自动地或者手动地执行。在SADL机器22处，承载片16可以被从传输平台14上移除，并且被铺放在SADL机器22的模块成形平台25上。承载片16可以被提供有多个工具/指引开口(未示出)，其可以被指引至SADL机器22从而便于承载片16适当定位和铺放在模块成形平台25上。
下一步可以操作铺放头机构托架36沿着拾取和铺放机器30的台架31上的导轨32滑动，从而将模块铺放头机构40的模块接合元件42直接定位于复合模块18之上。SADL机器22的模块成形平台25然后可以贴靠模块接合元件42的模块成形表面43升起，从而将平层复合模块18形成或塑造为模块成形表面43的一般凸形轮廓，经历模型挤压程序，如在图3的剖视图中所显示。将模块18成形或者塑形为模块接合元件42的模块成形表面43可以是自动的。额外的复合模块18按照分层的或者多层的方式，根据所需要实现的飞机机身蒙皮60(图1)的期望厚度，可以从FTLM机器2传输至SADL机器22的模块成形平台25，并且被成形为模块接合元件42的模块成形表面43。因此，连续的复合模块18可以铺放在彼此之上从而形成具有多层结构的层压模块18。取决于具体应用，模块铺放头机构40可以铺放连续纤维层或者连续织物层结合于复合模块18的编织层。在一些应用中，根据所属领域普通技术人员的知识，邻近的模块18可以彼此耦接。应该承认和理解的是，复合模块18不需要一直被成形于模块铺放头机构40上的模块接合元件42的模块成形表面43之上。在IML固化工具54的情形中，利用SADL机器22，模块18可以被直接成形在固化工具54上或者在其它蒙皮层之上。
在所期望数量的复合模块18已经堆放在拾取和铺放机器30的模块铺放头机构40上之后，为了检查复合模块18，检查扫描系统46的扫描仪49可以在模块接合元件42的模块成形表面43上横向移动。有缺陷的复合模块18可以被从模块铺放头机构40之中移除，并且被无缺陷的复合模块18所替代。对于模块铺放头机构40上的模块18的检查可以是自动的程序。
拾取和铺放机器30的铺放头机构托架36然后可以操作，在拾取和铺放机器30的台架31上的导轨32上横向移动，并且方便了叠加的、分层的、压缩的以及被检查过的复合模块18按照期望的位置被精确地铺放在固化工具54的模块铺放表面57上(图3)。额外的叠加的、分层的、压缩的模块18可以按照类似的方式而成形并且铺放在模块铺放表面57上的期望位置从而来形成飞机机身蒙皮60。邻近的模块18的模块边缘19可以倾斜并且重叠一个斜嵌槽(未示出)或者倾斜拼接点(未示出)，直到飞机机身蒙皮60被完全铺放好。
接下来参考图4中的流程图300，概述了模块化复合材料制造方法的说明性实施方式。该方法可以被用来例如但不局限于加工具有期望厚度的飞机机身蒙皮。在方框302中，复合模块可以被铺放。该模块可以是飞机机身蒙皮模块，其可以被用于加工例如但不局限于比方说飞机机身蒙皮的结构，并且可以使用例如但不局限于FTLM(平带铺放机器)进行铺放。另外地或者替换地，模块可以被用来加工例如但不局限于比方说机翼蒙皮、机头蒙皮、尾部蒙皮，在这种情形中，模块可以通过使用CTLM(起伏状铺放机器)来铺放。在方框304中，模块可以被输送至SADL(半自动加倍定位器)机器。在方框306中，模块可以被成形为飞机机身蒙皮或者其它结构的轮廓。在方框308中，在方框302、304和306中所实施的步骤可以被重复，从而形成飞机机身蒙皮或者其它结构的期望的厚度。在方框310中，模块可以被检查。在方框312中，叠加的或者分层的模块可以被叠加在固化工具上。该固化工具可以是例如但不局限于OML(外模生产线)或者IML(内模生产线)固化工具。在方框314中，在方框302、304、306、308、310和312中所实施的步骤可以根据需要重复，从而完全地铺放飞机机身蒙皮或者其它结构。
接下来参考图5和图6，本发明的实施方式可以被用在图5中所显示的飞机制造和服役方法78和图6中所显示的飞机94的情景中。在预备生产期间，示例性方法78可以包括飞机94的技术规格和设计80以及原材料采购82。在生产期间，进行飞机94的组件和子装配件制造84和系统集成86。随后，飞机94可以进行认证和交付88以就位服役90。在为客户服役的同时，飞机94也被规划进行日常维修和维护92(其可以还包括改型、改装、整修等等)。
方法78的各步骤可以由系统集成方、第三方、和/或操作者(例如，用户)进行或执行。为了便于说明，系统集成方可以包括数目不限的飞机制造商和主系统分包商；第三方可以包括数目不限的售卖方、分包商、和供应商；并且操作者可以是航空公司、租赁公司、军方、服务组织等。
如图6所示，由典型方法78制造的飞机94可以包括机体98，具有多个系统96和内部结构100。高级系统96的范例包括一个或多个推进系统102、电子系统104、液压系统106和环境系统108。可以包括任意数量的系统。尽管图示为一航空实施例，但本发明原理可以应用于其他行业，例如汽车行业。
这里实施的装置和方法可以在制造和服役方法78的任意一个或多个阶段中进行。例如，对应于生产过程84的组件或子装配件可以以类似于飞机94服役期间的组件或子装配件的方式制造或生产。同样，一个或多个装置实施例可以在生产阶段84和86期间被使用，例如，通过基本促进飞机94的组装或降低其成本。类似地，一个或多个装置实施例可以在飞机94处于服役阶段期间被使用，例如但不局限于在维修和服务92中。
如在前面提到的，模块化复合材料制造方法可以利用合适尺寸的装备从而来使得按照并行程序而不是串行地来铺放复合材料，作为复合飞机机身或者其它部件的加工的一部分。关于此事，我们来参考图7和图8。根据多个实施方式，制造复合结构的方法700可以包括铺放702多个模块18于工具54之上，这样模块18中的每一个都邻近于模块18中的至少另外一个，如在图9中所显示的，并且这样相邻的模块18被结合在一块，比如在连接点704处，从而形成复合结构。
在一些实施方式中，在基本上相同的时间，多于一个模块18可以被铺放在工具54之上；在这样的实施方式中，多个传输平台14可以被提供。另外，在形成复合结构过程中，模块18可以按照基本上顺序的方式而被铺放在工具54上，在后续模块18铺放在工具18上(如在图8中通过计数n-1所指示)的同时，在正向工具564上铺放的其中一个模块18(如在图8中通过计数n-2所指示)上执行铺放后程序706。在许多实施方式中，铺放步骤702以及铺放后程序706可以在随后的模块18正在被准备708(如在图8中通过计数n所指示的)用于铺放时而实施。
关于执行铺放后程序706，这可以包括检查710模块18中的一个，该模块已经被铺放在工具18上(如在图8中通过计数n-2所指示的)。执行铺放后程序706也可以包括处理形成在邻近的模块18之间的连接点704。在一些实施方式中，比如在图7和图8中所显示的，加工方法700可以包括在基本相同的时间，例如执行检查步骤710以及铺放后程序步骤706于不同的被铺放的模块18。
在许多实施方式中，铺放702模块18于工具54上可以包括装载712模块18于传输平台14上，指引714所装载的模块进入适当的位置，和/或然后铺放716模块于工具54之上。在所有的模块18已经被铺放于工具54上之后，并且任何随后的铺放后程序步骤706都已经被实施，然后结构可以被固化。
尽管本发明的实施方式已经被关于特定的示例性实施方式而被描述，应该理解的是特殊的实施方式是为了例证的目的而不是限制，其它的变型可以由所属领域普通技术人员所作出。

Claims (7)

1.一种模块化复合材料飞机蒙皮的制造方法，包括：
在第一制造过程中在第一模块制造机器上制造多个复合模块中的第一复合模块，所述第一复合模块包括相应的多个未固化板层；
在第二制造过程中在第二模块制造机器上制造多个复合模块中的第二复合模块，所述第二复合模块包括相应的多个未固化板层；
同时地进行所述第一制造过程和所述第二制造过程；
将未固化状态的所述第一复合模块施加至支撑结构；
将邻近所述第一复合模块的未固化状态的所述第二复合模块施加在所述支撑结构上以便所述第一复合模块的第一边缘和所述第二复合模块的第二边缘重叠以形成连接处以形成所述飞机蒙皮；和
固化所述飞机蒙皮。
2.如权利要求1所述的方法，其进一步包括给予所述多个复合模块中的每一个复合模块一个相应的轮廓。
3.如权利要求1所述的方法，其进一步包括沿相应的边缘彼此耦接所述多个复合模块中的邻近的模块。
4.如权利要求1所述的方法，其进一步包括将所述多个模块中的第三复合模块与所述多个模块中的第四复合模块水平地邻近，从而使所述第三复合模块的第三边缘与所述第四复合模块的第四边缘重叠以形成连接点，并且其中所述第三复合模块和所述第四复合模块基本上铺放在所述第一复合模块和所述第二复合模块之上。
5.如权利要求1所述的方法，其中复合模块进一步包括倾斜的模块边缘。
6.如权利要求1所述的方法，其中所述复合模块包括选自以下的材料：单向的碳纤维预浸渍体、碳纤维织物、玻璃纤维、玻璃纤维织物、聚芳醚醚酮或者聚芳醚醚酮织物。
7.如权利要求1所述的方法，其中进一步包括检查所述多个复合模块中的第三复合模块。
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EP2444240B1 (en) 2017-03-15
CN101492098A (zh) 2009-07-29
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PT2444240T (pt) 2017-04-06
US8916010B2 (en) 2014-12-23
ES2628443T3 (es) 2017-08-02
EP2067611B1 (en) 2012-02-08
JP5646141B2 (ja) 2014-12-24
KR20090060144A (ko) 2009-06-11
KR101511384B1 (ko) 2015-04-10
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JP2009137578A (ja) 2009-06-25
ATE544582T1 (de) 2012-02-15
EP2444240A1 (en) 2012-04-25

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