CN110723271A

CN110723271A - Apparatus and method for making composite structures and reacting to placement forces

Info

Publication number: CN110723271A
Application number: CN201910617491.7A
Authority: CN
Inventors: K·D·胡姆费尔德; A·B·卢布汉斯基
Original assignee: Boeing Co
Current assignee: Boeing Co
Priority date: 2018-07-16
Filing date: 2019-07-10
Publication date: 2020-01-24

Abstract

The present invention relates to an apparatus and method for making composite structures and reacting to placement forces. An apparatus for making a composite structure includes a tape placement machine including a delivery head configured to dispose a composite tape and a backing plate coupled to the tape placement machine and selectively positioned relative to the delivery head to react a placement force applied by the tape placement machine while the composite tape is being disposed.

Description

Apparatus and method for making composite structures and reacting to placement forces

Technical Field

The present disclosure relates generally to the manufacture of composite structures, and more particularly to an apparatus and method for arranging continuous composite tape to form a composite structure and reacting to placement forces associated with arranging the continuous composite tape.

Background

Composite structures are typically formed from a composite material that includes a reinforcement material disposed in a matrix material. The composite material is typically placed in a desired shape to form a composite structure. According to one conventional manufacturing method, composite materials are placed by placing a number of composite tapes in a desired shape to gradually build up layers of a composite structure. Such a manufacturing method may be automated using a tape placement machine configured to lay up multiple layers of the composite tape.

Depending on the desired application, certain composite structures include one or more stiffening members that prevent undesired movement, flexing, and vibration of the composite structure. In an example, a composite structure may include a composite panel and a number of composite stiffeners coupled to the composite panel. Typically, the composite panel and each composite stiffener are formed separately, such as according to the manufacturing method described above. After each of these components is formed, the composite reinforcement is placed on the composite panel, and the combined composite structure is then cured. However, when placing composite stiffeners onto composite panels, undesirable inconsistencies may be created in the composite structure.

Accordingly, those skilled in the art have continued research and development efforts in the field of composite structure fabrication.

Disclosure of Invention

In one example, the disclosed method for fabricating a composite structure includes the steps of: (1) laying up successive segments of composite tape on the composite panel with a delivery head of a tape placement machine to form a flange portion of an initial ply of the composite reinforcement; (2) positioning a backing plate coupled to the delivery head relative to the delivery head; and (3) further laying up the continuous segments of the composite tape on the backing plate with the delivery head to form a web portion of the initial plies of the composite stiffener.

In one example, a portion of an aircraft assembled according to a method is disclosed, the method comprising the steps of: (1) laying up successive segments of composite tape on the composite panel with a delivery head of a tape placement machine to form a flange portion of an initial ply of the composite reinforcement; (2) positioning a backing plate coupled to the delivery head relative to the delivery head; and (3) further laying up the continuous segments of the composite tape on the backing plate with a deposition head to form a web portion of the initial plies of the composite stiffener.

In one example, a disclosed method for reacting a placement force applied by a tape placement machine that lays up composite tape includes the steps of: (1) coupling a back plate to a delivery head of the tape placement machine with a reaction structure; (2) selectively positioning the backing plate relative to the delivery head with a drive assembly; (3) laying up the composite tape on the backing plate with the delivery head; (4) applying, by the delivery head, the placement force to the composite tape as the composite tape is laid up on the backing plate with the delivery head; and (5) reacting the placement force to and from the reaction structure back to the delivery head through the backing plate when the composite tape is laid up on the backing plate with the delivery head.

In one example, a portion of an aircraft assembled according to a method is disclosed, the method comprising the steps of: (1) coupling a backing plate to a delivery head of the tape placement machine with a reaction structure; (2) selectively positioning the backing plate relative to the delivery head with a drive assembly; (3) laying up the composite tape on the backing plate with the delivery head; (4) applying, by the delivery head, the placement force to the composite tape as the composite tape is laid up on the backing plate with the delivery head; and (5) when the composite tape is laid up on the backing plate with the delivery head, reacting the placement force through the backing plate to the reaction structure and from the reaction structure back to the delivery head.

In one example, the disclosed method for fabricating a composite structure includes the steps of: the method includes laying up a flange portion, a web portion, a supplemental web portion, and a supplemental flange portion in successive segments of a composite tape with a tape placement machine to form a composite stiffener on a composite panel while reacting placement forces applied to the web portion and the supplemental web portion by compaction rollers of the tape placement machine back to the tape placement machine.

In one example, a portion of an aircraft assembled according to a method is disclosed, the method comprising the steps of: the method includes laying up flange portions, web portions, supplemental web portions, and supplemental flange portions in successive segments of a composite tape with a tape placement machine to form composite stiffeners on composite panels while reacting placement forces applied to the web portions and the supplemental web portions by compaction rollers of the tape placement machine back to the tape placement machine.

In one example, a disclosed method for fabricating a composite structure including a composite panel and an integral composite stiffener includes the steps of: (1) laying up the composite panel on a mandrel using a tape placement machine; (2) positioning a backing plate coupled to a delivery head of the tape placement machine to support a portion of the web of the composite stiffener; and (3) laying the portion of the web on the backing plate with the backing plate reacting a placement force into the delivery head.

In one example, a portion of an aircraft assembled according to a method is disclosed, the method comprising the steps of: (1) laying up the composite panel on a mandrel using a tape placement machine; (2) positioning a backing plate coupled to a delivery head of the tape placement machine to support a portion of the web of the composite stiffener; and (3) laying the portion of the web on the backing plate with the backing plate reacting a placement force into the delivery head.

In one example, a disclosed apparatus for fabricating a composite structure includes a tape placement machine including a delivery head configured to arrange a composite tape; and a backing plate coupled to the tape placement machine and selectively positioned relative to the delivery head to react a placement force applied by the tape placement machine when the composite tape is being placed.

In an example, a method for fabricating a portion of an aircraft using an apparatus is disclosed, the apparatus comprising a tape placement machine including a delivery head configured to arrange a composite tape; and a backing plate coupled to the tape placement machine and selectively positioned relative to the delivery head to react a placement force applied by the tape placement machine when the composite tape is being placed.

In one example, the disclosed apparatus for fabricating a composite structure includes a mandrel to support formation of a composite panel of the composite structure. The apparatus also includes a tape placement machine including a delivery head configured to dispose a composite tape and a compaction roller configured to apply a placement force when disposing the composite tape. The apparatus also includes a backing plate coupled to the delivery head and selectively movable relative to the delivery head to support formation of a composite stiffener extending from the composite panel. The backing plate reacts the placement force back to the delivery head when the delivery head places the composite tape on the backing plate.

In one example, a method for fabricating a portion of an aircraft using an apparatus including a mandrel to support formation of a composite panel of the composite structure is disclosed. The apparatus also includes a tape placement machine including a delivery head configured to dispose a composite tape and a compaction roller configured to apply a placement force when disposing the composite tape. The apparatus also includes a backing plate coupled to the delivery head and selectively movable relative to the delivery head to support formation of a composite stiffener extending from the composite panel. The backing plate reacts the placement force back to the delivery head when the delivery head places the composite strip on the backing plate.

In one example, a composite structure fabricated using a tape placement machine including a delivery head and a backing plate movably coupled with the delivery head is disclosed, the composite structure including a composite face plate and a composite stiffener formed in situ on the composite face plate and including a web formed on and extending from the backing plate.

The present disclosure also includes the following clauses:

clause 1: a method 1000 for fabricating a composite structure 300, the method 1000 comprising laying up continuous segments 342 of a composite tape 104 on a composite panel 302 with a delivery head 114 of a tape placement machine 102 to form flange portions 304 of initial plies 306 of a composite stiffener 308; positioning back plate 106 coupled to delivery head 114 relative to the delivery head 114 and composite face plate 302; and further laying up the continuous segments 342 of the composite tape 104 on the backing plate 106 using the delivery head 114 to form a web portion 310 of the initial plies 306 of the composite stiffener 308.

Clause 2: the method 1000 of clause 1, further comprising fixing the position of the backing plate 106 relative to the composite face plate 302; and moving the delivery head 114 relative to the back plate 106 while laying up the continuous segments 342 of the composite tape 104 on the back plate 106 to form the web portion 310 of the initial plies 306 of the composite stiffeners 308.

Clause 3: the method 1000 of clauses 1 or 2, further comprising repositioning the back plate 106 to the side of the web portion 310 of the initial ply 306 opposite the delivery head 114; further laying up the continuous segments 342 of the composite tape 104 on the web portion 310 of the initial plies 306 supported by the back plate 106 with the delivery head 114 to form a supplemental web portion 312 of the initial plies 306 of the composite stiffener 308; and further laying up the continuous segments 342 of the composite tape 104 on the composite panel 302 using the delivery head 114 to form the supplemental flange portions 314 of the initial plies 306 of the composite stiffener 308.

Clause 4: the method 1000 of clause 3, further comprising folding the continuous segment 342 of the composite tape 104 to transition from the web portion 310 of the initial ply 306 to the supplemental web portion 312 of the initial ply 306.

Clause 5: the method 1000 of clauses 3 or 4, further comprising fixing the position of the delivery head 114 relative to the composite panel 302 to support the orientation of the web portion 310 of the initial plies 306 of the composite stiffener 308; moving the back plate 106 relative to the delivery head 114 to separate the back plate 106 from the first surface 316 of the web portion 310 of the initial ply 306; moving the back plate 106 relative to the delivery head 114 into contact with a second surface 350 of the web portion 310 of the initial ply 306, the second surface 350 of the web portion 310 of the initial ply 306 being opposite the first surface 316 of the web portion 310 of the initial ply 306; and supporting the web portion 310 of the initial lay-up 306 with the back plate 106 while the composite tape 104 is laid over the web portion 310 of the initial lay-up 306 to form the supplemental web portion 312 of the initial lay-up 306 of the composite stiffener 308.

Clause 6: the method 1000 of clause 5, further comprising fixing a position of the back plate 106 relative to the web portion 310 of the initial plies 306 of the composite stiffener 308; and moving the delivery head 114 relative to the back plate 106 while laying up the continuous segments 342 of the composite tape 104 on the web portion 310 to form the supplemental web portion 312 of the initial plies 306 of the composite stiffener 308.

Clause 7: the method 1000 of any of clauses 3-6, further comprising while laying up a plurality of subsequent continuous segments 344 of the composite tape 104 on the initial ply 306 with the delivery head 114 to form a plurality of subsequent plies 320 of the composite reinforcement 308.

Clause 8: the method 1000 of clause 7, further comprising positioning the back sheet 106 behind the supplemental web portion 312 of the initial plies 306 of the composite stiffener 308; and laying up a first of the subsequent consecutive segments 344 of the composite tape 104 on the web portion 310 of the initial ply 306 of the composite stiffener 308 supported by the back plate 106 with the delivery head 114 to form a web portion 322 of a first of the subsequent plies 320 of the composite stiffener 308.

Clause 9: the method 1000 of clause 8, further comprising positioning the back plate 106 behind the web portion 310 of the initial plies 306 of the composite stiffener 308; and further laying up the first of the subsequent consecutive segments 344 of the composite tape 104 over the supplemental web portion 312 of the initial ply 306 supported by the backing plate 106 with the delivery head 114 to form a supplemental web portion 326 of the first of the subsequent plies 320 of the composite stiffener 308.

Clause 10: the method 1000 of clause 8, further comprising positioning the back plate 106 behind the web portion 310 of the initial plies 306 of the composite stiffener 308; and laying up a second one of the subsequent continuous segments 344 of the composite tape 104 on the supplemental web portion 312 of the initial ply 306 supported by the back plate 106 with the delivery head 114 to form a supplemental web portion 326 of the first one of the subsequent plies 320 of the composite stiffener 308.

Clause 11: the method 1000 of any of clauses 7-10, further comprising laying the composite panel 302 on a mandrel 116; and placing radius fillers 338 on the composite panel 302 prior to laying up the composite tape 104 to form the composite stiffener 308.

Clause 12: an apparatus 100 for making a composite structure 300, the apparatus 100 comprising a tape placement machine 102, the tape placement machine 102 comprising a delivery head 114 configured to dispose a composite tape 104; and a backing plate 106, the backing plate 106 coupled to the delivery head 114 and selectively positioned relative to the delivery head 114 to react a placement force 112 applied by the tape placement machine 102 when the composite tape 104 is being placed.

Clause 13: apparatus 100 according to clause 12, further comprising a first linear axis of motion 168, and wherein backing plate 106 is linearly movable relative to delivery head 114 along first linear axis of motion 168.

Clause 14: the apparatus 100 of clause 13, further comprising a first rotational axis of motion 162, and wherein the backing plate 106 is rotationally movable relative to the delivery head 114 about the first rotational axis of motion 162.

Clause 15: the apparatus 100 of clause 13, further comprising a second linear motion axis 170, the second linear motion axis 170 being perpendicular to the first linear motion axis 168, and wherein the back plate 106 is linearly movable relative to the delivery head 114 along the second linear motion axis 170.

Clause 16: the apparatus 100 of clause 15, further comprising a third linear axis of motion 172, the third linear axis of motion 172 being perpendicular to the first and/or second linear axis of motion 170, and wherein the back plate 106 is linearly movable relative to the delivery head 114 along the third linear axis of motion 172.

Clause 17: the apparatus 100 of clause 14, further comprising a second rotational axis of motion 164, the second rotational axis of motion 164 being perpendicular to the first rotational axis of motion 162, and wherein the back plate 106 is rotationally movable relative to the delivery head 114 about the second rotational axis of motion 164.

Clause 18: the apparatus 100 of clause 17, further comprising a third rotational axis of motion 166, the third rotational axis of motion 166 being parallel to the first rotational axis of motion 162, and wherein the back plate 106 is rotationally movable relative to the delivery head 114 about the third rotational axis of motion 166.

Clause 19: the apparatus 100 of any of clauses 12-18, further comprising a reaction structure 226, the reaction structure 226 coupled to the delivery head 114 and the backing plate 106 and configured to transfer the placement force 112 from the backing plate 106 back to the delivery head 114; and a drive assembly 174 operably coupled with reaction structure 226 and configured to linearly move backing plate 106 relative to delivery head 114 and rotationally move backing plate 106 relative to delivery head 114.

Clause 20: a composite structure 300 fabricated using a tape placement machine 102, the tape placement machine 102 comprising a delivery head 114 and a backing plate 106 movably coupled with the delivery head 114, the composite structure 300 comprising: a composite panel 302; and a composite stiffener 308, the composite stiffener 308 being formed in situ on the composite face sheet 302 and comprising a web 328 formed on the backing sheet 106 and extending from the composite face sheet 302.

Clause 21: the composite structure 300 of clause 20, wherein the web 328 of the composite stiffener 308 includes a plurality of plies 334 of composite tape 104 arranged on the backing plate 106 by the delivery head 114; each of the plies 334 partially forms a web portion 310 of the web 328 and a complementary web portion 312 of the web 328; and at least some of the plies 334 are shared by the composite stiffener 308 and the composite panel 302.

Clause 22: a method 2000 for reacting a placement force 112 applied by a tape placement machine 102 that lays up a composite tape 104, the method 2000 comprising coupling a backing plate 106 to a delivery head 114 of the tape placement machine 102 with a reaction structure 226; selectively positioning backing plate 106 relative to delivery head 114 using drive assembly 174; laying up the composite tape 104 on the backing sheet 106 with the delivery head 114; applying the placement force 112 to the composite tape 104 by the delivery head 114 while the composite tape 104 is being laid up on the backing plate 106 with the delivery head 114; and reacting the placement force 112 through the backing plate 106 to the reaction structure 226 and from the reaction structure 226 back to the delivery head 114 when the composite tape 104 is laid up on the backing plate 106 with the delivery head 114.

Clause 23: the method 2000 of clause 22, further comprising: fixing the position of the backing plate 106 relative to the delivery head 114 prior to laying the composite tape 104 on the backing plate 106; and moving the delivery head 114 relative to the backing plate 106 while laying the composite tape 104 on the backing plate 106.

Clause 24: a method 3000 for fabricating a composite structure 300, the method 3000 comprising laying up flange portions 304, web portions 310, supplemental web portions 312, and supplemental flange portions 314 in successive segments 342 of a composite strip 104 with a strip placement machine 102 to partially form composite stiffeners 308 on composite panels 302 while reacting a placement force 112 applied to the web portions 310 and the supplemental web portions 312 by compaction rollers 124 of the strip placement machine 102 back to the strip placement machine 102.

Clause 25: the method 3000 of clause 24, further comprising folding the continuous segment 342 of the composite strip 104 to transition from the web portion 310 to the supplemental web portion 312.

Clause 26: the method 3000 of clauses 24 or 25, further comprising laying up the continuous section 342 of the composite tape 104 over the radius filler 338 on the composite panel 302 with the tape placement machine 102 while transitioning from the flange portion 304 to the web portion 310 and while transitioning from the supplemental web portion 312 to the supplemental flange portion 314.

Clause 27: a method 4000 for fabricating a composite structure 300, the fabricated composite structure 300 comprising a composite panel 302 and an integral composite stiffener 308, the method 4000 comprising:

laying up the composite panel 302 on a mandrel 116 using a tape placement machine 102; positioning a backing plate 106 coupled to a delivery head 114 of the tape placement machine 102 to support a portion of a web 328 of the composite stiffener 308; and laying the portion of the web 328 over the backing plate 106 with the backing plate 106 reacting the placement force 112 into the delivery head 114.

Clause 28: the method 4000 of clause 27, further comprising repositioning the backing plate 106 to an opposite side of the portion of the web 328 to support a supplemental portion of the web 328 of the composite stiffener 308; and laying the supplemental portion of the web 328 over the portion of the web 328 with the backing plate 106 reacting the placement force 112 into the delivery head 114.

Clause 29: the method 4000 of clause 28, wherein the portion of the web 328 and the supplemental portion of the web 328 are formed from a continuous segment 342 of the composite strip 104; and the method further comprises: supporting the continuous segment 342 of the composite tape 104 with the delivery head 114 after forming the portion of the web 328; and folding the continuous segment 342 of the composite tape 104 to transition from the portion of the web 328 to the supplemental portion of the web 328.

Clause 30: an apparatus 100 for making a composite structure 300, the apparatus 100 comprising a mandrel 116 to support formation of a composite panel 302 of the composite structure 300; a tape placement machine 102, the tape placement machine 102 including a delivery head 114 and a compaction roller 124, the delivery head 114 configured to dispose the composite tape 104, the compaction roller 124 configured to apply a placement force 112 when disposing the composite tape 104; and backing plate 106, said backing plate 106 coupled to said delivery head 114 and selectively movable relative to said delivery head 114 to support formation of composite stiffeners 308 extending from said composite face plate 302; wherein the backing plate 106 reacts the placement force 112 back to the delivery head 114 when the delivery head 114 disposes the composite tape 104 on the backing plate 106.

Clause 31: the apparatus 100 of clause 30, further comprising a reaction structure 226, the reaction structure 226 coupling the backing plate 106 to the delivery head 114, wherein the placement force 112 is transferred from the backing plate 106 to the delivery head 114 via the reaction structure 226.

Clause 32: the apparatus 100 of clause 31, wherein the reaction structure 226 includes: a support mount 176, the support mount 176 coupled to the delivery head 114; an arm 178, the arm 178 movably coupled with the support mount 176, wherein the back plate 106 is movably coupled with the arm 178 opposite the support mount 176; and a drive assembly 174, the drive assembly 174 configured to selectively move the arm 178 relative to the support mount 176 and to selectively move the back plate 106 relative to the support mount 176 and the arm 178.

Clause 33: the apparatus 100 of clause 32, wherein the drive assembly 174 comprises an arm rotation actuator 204, the arm rotation actuator 204 operably coupling the arm 178 and the support mount 176 and configured to rotationally move the backing plate 106 relative to the delivery head 114 about the first rotational axis of motion 162.

Clause 34: the apparatus 100 of clauses 32 or 33, wherein the drive assembly 174 comprises an arm linear actuator 202, the arm linear actuator 202 operably coupled with the arm 178 and configured to linearly move the backing plate 106 relative to the delivery head 114 about the first linear axis of motion 168.

Clause 35: the apparatus 100 of clauses 32, 33 or 34, wherein the drive assembly 174 comprises a plate linear actuator 206, the plate linear actuator 206 operably coupling the back plate 106 and the arm 178 and configured to linearly move the back plate 106 relative to the delivery head 114 along at least one of the second linear axis of motion 170 and the third linear axis of motion 172.

Clause 36: the apparatus 100 of any of clauses 32-35, wherein the support mount 176 includes an angle track 184; and drive assembly 174 comprises a carriage 186, the carriage 186 operably coupling the arm 178 and the angular track 184 and configured to rotationally move the back plate 106 relative to the delivery head 114 about a second rotational axis 164.

Clause 37: the apparatus 100 of any of clauses 32-36, wherein the drive assembly 174 comprises a plate rotation actuator 208, the plate rotation actuator 208 operably coupling the backing plate 106 with the arm 178 and configured to rotationally move the backing plate 106 relative to the delivery head 114 about a third rotational axis of motion 166.

Clause 38: a portion of an aircraft 1200 assembled according to the method of any of clauses 1-11, 22-23, 24-26 or 27-29.

Clause 39: a method for making a portion of an aircraft 1200 using the apparatus 100 of any of clauses 12-19 or 30-37.

Other examples of the disclosed apparatus and methods will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Drawings

FIG. 1 is a schematic perspective view of an example of a disclosed composite structure;

FIG. 2 is a schematic elevational cross-sectional view of an example of the disclosed composite structure;

FIG. 3 is a schematic elevational cross-sectional view of an example of the disclosed composite structure;

FIG. 4 is a schematic elevational cross-sectional view of an example of the disclosed composite structure;

FIG. 5 is a schematic block diagram of the disclosed apparatus for fabricating a composite structure;

FIG. 6 is a schematic front view of an example of the disclosed apparatus reacting a placement force;

FIG. 7 is a schematic elevational view of an example of the disclosed apparatus;

FIG. 8 is a schematic elevational view of an example of the disclosed apparatus;

FIG. 9 is a schematic elevational view of an example of the disclosed apparatus;

FIG. 10 is a schematic partial perspective view of an example of the disclosed composite structure;

FIG. 11 is a schematic perspective view of an example of the disclosed apparatus;

FIG. 12 is a schematic perspective view of an example of the disclosed apparatus;

FIG. 13 is a schematic perspective view of an example of the disclosed apparatus;

FIG. 14 is a schematic perspective view of an example of the disclosed apparatus;

FIG. 15 is a schematic perspective view of an example of a back plate and a portion of a reaction structure of the disclosed device;

FIG. 16 is a flow chart of an example of the disclosed method for fabricating a composite structure;

17-30 are schematic elevational views of examples of the disclosed apparatus illustrating various steps of the disclosed method of FIG. 16;

FIG. 31 is a schematic partial perspective view of an example of the disclosed composite structure;

FIG. 32 is a schematic partial perspective view of an example of the disclosed composite structure;

FIG. 33 is a flow chart of an example of the disclosed method for reacting a placement force applied by a tape placement machine of a laminated composite tape;

FIG. 34 is a flow chart of an example of the disclosed method for fabricating a composite structure;

FIG. 35 is a flow chart of an example of the disclosed method for fabricating a composite structure;

FIG. 36 is a flow chart of an example aircraft production and service method; and

FIG. 37 is a schematic block diagram of another example of an aircraft.

Detailed Description

The following detailed description refers to the accompanying drawings that illustrate specific examples described by the disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numbers may refer to the same feature, element, or component in different figures.

Illustrative, non-exhaustive examples that may be, but are not necessarily, claimed in accordance with the subject matter of the present disclosure are provided below.

The present disclosure provides examples of apparatus and methods for fabricating composite structures. Such a composite structure includes at least a first portion to extend from or stand up relative to the first portion and a second portion. Such apparatus and methods may be used to form composite structures without the need for complex and expensive tools configured to correspond to the shape of different portions of the composite structure. Furthermore, such an apparatus and method enables the in situ formation of the upstanding second portion of the composite structure.

Referring to fig. 1, an example of a composite structure 300, such as a composite structure fabricated using the apparatus and methods disclosed herein, is disclosed. In an example, composite structure 300 includes composite panel 302. In some examples, composite panel 302 is flat. In some examples, composite panel 302 is curved/bent. Composite structure 300 also includes a number of composite stiffener(s) 308 coupled to composite panel 302. In this example, composite panel 302 may be an example of a first portion 358 of composite structure 300 and composite stiffener 308 may be an example of a second portion 360 of composite structure 300.

Composite stiffener 308 may be generally referred to as a blade (blade) stiffener or blade stringer. In an example, each of the composite stiffeners 308 includes a web 328 that stands up on an inner surface 330 of the composite panel 302 or protrudes from the inner surface 330 of the composite panel 302. In the illustrative example, composite stiffener 308 is approximately perpendicular relative to where the base of web 328 of composite stiffener 308 is located on inner surface 330.

In accordance with the apparatus and methods disclosed herein, in some examples, composite stiffeners 308 are formed in situ on composite panel 302. In some examples, at least a portion of composite stiffener 308 is integral with composite panel 302. In other words, both composite panel 302 and composite stiffener 308 share at least some plies or layers of composite material. Thus, in some examples, composite structure 300 includes composite panel 302 with composite stiffeners 308 integral with composite panel 302 (i.e., a composite panel with integral composite stiffeners 308).

In one example, the composite structure 300 illustrated in fig. 1 is a portion of a wing of an aircraft. In other examples, composite structure 300 may be used as part of other airfoils, aircraft body panels, or other components for aerospace vehicles and structures, structural components for automobiles, marine vehicles or other vehicles, and the like. In some examples, the composite structure 300 may define complex geometries (such as one or more contours that curve about multiple axes), define curves, holes, or other irregular shapes, and so forth.

In an example, composite panel 302 is a composite skin panel of an aircraft, and composite stiffeners 308 are composite stringers coupled to the composite skin panel. The present disclosure recognizes that aircraft generally include a fuselage, which may be considered a basic skeleton, to which composite skin panels are attached to form a smooth aerodynamic outer surface. Similarly, the wing of the aircraft also comprises a base structure covered with a composite skin panel. Typically, composite skin panels are light and thin to minimize the weight of the aircraft and increase its payload and range. Because skin panels are thin, they are generally flexible and often provided with stiffeners to prevent unwanted movement, flexing, and vibration during flight. Aircraft composite skin panels are often provided with composite stringers to provide the desired reinforcement. The composite stringers are essentially upstanding ribs that are fixedly attached to the underside of the composite panel (also referred to as "inner mold line" or IML) and are generally perpendicular to the plane of the composite panel. The stringers effectively take the form of flat panels having a relatively low stiffness in bending and substantially increase the bending stiffness. The composite stringers may have a variety of cross-sectional shapes, including those commonly referred to as S-shaped stringers, I-shaped stringers, C-shaped stringers, T-shaped stringers, J-shaped stringers, back-to-back stringers, straight stringers, blade stringers, and any other non-closed cross-sectional shape. The amount of additional stiffness provided by a stringer depends on its size, shape, thickness, and spacing of adjacent stringers.

The present disclosure also recognizes that in the case of composite aircraft, composite skin panels with composite stringers can be complex, given that the composite panels are cured carbon fiber composite materials, and that the elongate structural shapes of the composite materials are generally not produced using the same processes as those used for the structural shapes of metals. Alternatively, the structural shape of the composite material is typically produced by thermally curing several different plies of the composite material together in a form that provides the desired shape, or by co-consolidating layers of thermoplastic plastic. These processes can involve many parts and can be somewhat labor intensive. Thus, fabricating a composite skin panel with co-cured composite stringers may involve significant time and complexity, which increases the cost of the aircraft.

Advantageously, the apparatus and method disclosed herein have been developed to provide a reinforced composite structure that reduces the complexity associated with fabrication by enabling in-situ formation of composite stiffeners directly on the surface of the composite panel.

Fig. 2-4 are schematic cross-sectional views of examples of composite stiffeners 308 coupled to a portion of composite panel 302 as shown. In some examples, as illustrated in fig. 2 and 3, the composite stiffener 308 includes a flange 332 and a web 328. In these examples, flange 332 is disposed along inner surface 330 of composite panel 302, and web 328 extends from flange 332. In these examples, the flange 332 of the composite stiffener 308 may be an example of the first portion 358 of the composite structure 300, and the web 328 of the composite stiffener 308 may be an example of the second portion 360 of the composite structure 300.

In some examples, as illustrated in fig. 4, composite stiffener 308 includes a web 328. In these examples, web 328 is disposed along an inner surface 330 of composite panel 302 and extends from inner surface 330 of composite panel 302. In these examples, the portion of the composite panel 302 adjacent to the base of the web 328 may be an example of the first portion 358 of the composite structure 300, and the web 328 of the composite stiffener 308 may be an example of the second portion 360 of the composite structure 300, for example.

In some examples, web 328 is oriented approximately perpendicularly with respect to flange 332 and/or inner surface 330 of composite panel 302 (i.e., web 328 extends approximately perpendicularly from flange 332 and/or composite panel 302). In other examples, web 328 is oriented at any of a variety of angles relative to flange 332 and/or inner surface 330 of composite panel 302.

In the example of the composite stiffener 308, as illustrated in fig. 2, the web 328 is located at a middle portion of the flange 332 (e.g., between the ends of the flange 332), the flange 332 extends outwardly from opposite sides of the web 328, and the web 328 terminates at a free distal end 362. This beam structure or shape of the composite stiffener 308 is commonly referred to as a blade spar having an inverted T-shaped cross-section or a back-to-back L-shaped cross-section.

In some examples, as illustrated in fig. 2, the composite stiffener 308 includes a stiffener flange portion 390, the stiffener flange portion 390 being located on the composite panel 302, and the stiffener flange portion 390 sharing at least some plies 334 of the composite tape 104 with the inner surface 330 of the composite panel 302. The composite stiffener 308 also includes a stiffener web portion 392 that extends (e.g., perpendicularly) from the stiffener flange portion 390, and the stiffener web portion 392 shares at least some of the plies 334 of the composite strip 104 with the stiffener flange portion 390. The composite stiffener 308 also includes a stiffener supplemental web portion 394 that is in contact with, opposite, and parallel to the stiffener web portion 392, and the stiffener supplemental web portion 394 shares at least some of the plies 334 of the composite strap 104 with the stiffener web portion 392. The composite stiffener 308 also includes a stiffener supplemental flange portion 396 that extends (e.g., perpendicularly) from the stiffener supplemental web portion 394 opposite the stiffener flange portion 390, and the stiffener supplemental flange portion 396 shares at least some of the plies 334 with the stiffener supplemental web portion 394. In other words, in some examples, at least some of the plurality of plies 334 forming the composite panel 302 and the composite stiffener 308 are shared by the flange 332 and web 328 of the composite stiffener 308 and the inboard portion of the composite panel 302.

In another example of the composite stiffener 308, as illustrated in fig. 3, the web 328 is located at the end of a flange 332 that extends outward from one side of the web 328, and the flange terminates at a free distal end 362. This beam structure or shape of the composite stiffeners 308 is commonly referred to as a stringer having an L-shaped cross-section.

In some examples, as illustrated in fig. 3, the composite stiffener 308 includes a stiffener flange portion 390, the stiffener flange portion 390 being located on the composite panel 302, and the stiffener flange portion 390 sharing at least some plies 334 of the composite tape 104 with the inner surface 330 of the composite panel 302. The composite stiffener 308 also includes a stiffener web portion 392 that extends (e.g., perpendicularly) from the stiffener flange portion 390, and the stiffener web portion 392 shares at least some of the plies 334 of the composite strip 104 with the stiffener flange portion 390. In other words, in some examples, at least some of the plurality of plies 334 forming the composite panel 302 and the composite stiffener 308 are shared by the flange 332 and web 328 of the composite stiffener 308 and the inboard portion of the composite panel 302.

In another example (not shown) of the composite stiffener 308, the web 328 is located at the tip of a flange 332 that extends outwardly from one side of the web 328, and a second flange is located at the distal end of the web 328 and extends outwardly from the opposite side of the web 328, commonly referred to as a stringer having a Z-shaped cross-section.

In the example of composite stiffener 308, as illustrated in fig. 4, web 328 is located directly on an inner surface 330 of composite panel 302, web 328 extends outwardly from inner surface 330 of composite panel 302, and web 328 terminates at a free distal end 362. This configuration or shape of the composite stiffeners 308 is commonly referred to as a blade stringer.

In some examples, as illustrated in fig. 4, the composite stiffener 308 includes a stiffener web portion 392 that extends (e.g., perpendicularly) from the composite panel 302, and the stiffener web portion 392 shares at least some plies 334 of the composite tape 104 with the inner surface 330 of the composite panel 302. The composite stiffener 308 also includes a stiffener supplemental web portion 394 that is in contact with, opposite, and parallel to the stiffener web portion 392, and that the stiffener supplemental web portion 394 shares at least some of the plies 334 of the composite strap 104 with the stiffener web portion 392 and the inner surface 330 of the composite panel 302. In other words, in some examples, at least some of the plurality of plies 334 forming the composite panel 302 and the composite stiffener 308 are shared by the web 328 of the composite stiffener 308 and the inboard portion of the composite panel 302.

Referring to fig. 2-4, in some examples, the flange 332 and the web 328 of the composite stiffener 308 include or are formed from a plurality of plies 334 of the composite tape 104, the plurality of plies 334 of the composite tape 104 being coupled (e.g., bonded) to each other and to the inner surface 330 of the composite panel 302. In some examples, at least a portion of the composite panel 302 is a lay-up of a plurality of continuous layers or plies 336 of composite material (such as a sheet of carbon fibers impregnated with a resin material), the plurality of continuous layers or plies 336 of composite material being laid one atop the other. In some examples, the composite panel 302 is a lay-up of multiple continuous layers or plies 334 of the composite tape 104 laid one on top of the other, for example, using the tape placement machine 102 (fig. 1). Each section of the composite reinforcement 308 is a lay-up of multiple continuous layers or plies 334 of the composite tape 104, the multiple continuous layers or plies 334 of the composite tape 104 being laid one on top of the other. The composite stiffener 308 and composite panel 302 are then co-cured together into a single unit.

In some examples, as illustrated in fig. 2 and 3, the continuous plies 334 of the composite strip 104 forming the flange 332 (e.g., the reinforcement flange portion 390 and/or the reinforcement supplemental flange portion 396) are bent together upward into the upstanding web 328 (e.g., the reinforcement web portion 392 and the reinforcement supplemental web portion 394, respectively). In some examples, as illustrated in fig. 4, some of the continuous plies 334 of the composite tape 104 forming the composite panel 302 are bent together upwardly into an upstanding web 328 (e.g., a stiffener web portion 392 and a stiffener supplemental web portion 394, respectively). In other words, portions of the lay-up of the continuous plies 334 of the composite strip 104 are bent upwardly against each other, with the lay-up being bonded together to form the web 328.

In some examples, as illustrated in fig. 2 and 3, the portion of the composite stiffener 308 that forms the transition 364 from the flange 332 to the web 328 is arcuate (e.g., the transition from the stiffener flange portion 390 to the stiffener web portion 392 and the transition from the stiffener supplemental flange portion 396 to the stiffener supplemental web portion 394). The curvature of transition 364 has a radius. The radius of the bend forming the transition 364 is the radius of the transition between the portion of the flange 332 and the portion of the web 328 formed by the outermost layer of the composite strip 104 forming the composite stiffener 308.

In some examples, as illustrated in fig. 4, the portions of composite stiffener 308 that form transition 364 from composite panel 302 to web 328 are arcuate (e.g., the transition from inner surface 330 of composite panel 302 to stiffener web portion 392 and the transition from stiffener supplemental flange portion 396 to inner surface 330 of composite panel 302). The curvature of transition 364 has a radius. The radius of the bend forming the transition 364 is the radius of the transition between the portion of the composite panel 302 and the portion of the web 328 formed by the inner surface 330 of the composite panel 302 and the outermost layer of the composite strip 104 forming the composite stiffener 308.

In some examples, after each of the plies 334 of the composite strip 104 is placed to form a respective layer of the stiffener web portion 392 of the web 328, each of the plies 334 is folded over itself at the distal end 362 of the web 328 to form a respective layer of the stiffener supplemental web portion 394 of the web 328. In other words, each of the plies 334 of the composite strip 104 forms a continuous respective layer of the reinforcement web portion 392 and the reinforcement supplemental web portion 394. This lay-up configuration may be used to form a composite stiffener 308 having an inverted T-shaped cross-section.

In some examples, the first plurality of plies 334 are placed to form some or all of the respective layers of the stiffener web portion 392 of the web 328. After at least some of the first plurality of plies 334 are placed, a second plurality of plies 334 are placed to form respective layers of stiffener supplemental web portions 394 of the web 328. In other words, each of the first plurality of plies 334 of the composite strip 104 forms a continuous respective layer of the stiffener web portion 392, and each of the second plurality of plies 334 forms a continuous respective layer of the stiffener supplemental web portion 394. This lay-up configuration may be used to form a composite stiffener 308 having a back-to-back L-shaped cross-section.

Referring to fig. 5 and 6, an example of an apparatus 100 for fabricating or otherwise forming a composite structure 300 is disclosed. The apparatus 100 is configured for arranging the composite tape 104 during formation of the composite structure 300. The apparatus 100 may be used to form composite structures of various material classes and with various configurations and shapes.

For purposes of this disclosure, the terms "dispose," "disposing," and similar terms have their ordinary meaning as understood by those skilled in the art and include placing an item in a particular or suitable arrangement, location, or place. Throughout this disclosure, phrases such as "arranging a composite tape," "to arrange a composite tape," and similar phrases refer to selectively placing a composite tape in a particular position and/or orientation relative to another article. In one example, placing the composite tape includes laying down a quantity (one or more) of the composite tape on a surface of the article along a predetermined placement path, commonly referred to as "laying up" the composite tape. Thus, throughout this disclosure, the terms "arrange," "place," "lay," and similar terms may be used interchangeably.

In an example, the apparatus 100 includes a tape placement machine 102. The tape placement machine 102 is configured to place (e.g., place or lay down) the composite tape 104. The tape placement machine 102 is selectively positioned and/or selectively oriented, also referred to herein as selectively positioned, relative to a placement surface 222 on which the composite tape 104 is disposed. In other words, the tape placement machine 102 is configured to move relative to the placement surface 222 when the composite tape 104 is disposed. As the composite tape 104 is disposed on the placement surface 222 by the tape placement machine 102, the tape placement machine 102 applies a placement force 112 to the composite tape 104 and thus to the placement surface 222. While the composite strip 104 is generally described herein as being disposed "on" the placement surface 222, it should be appreciated that one layer of the composite strip 104 is disposed directly on the placement surface 222, and each subsequent layer of the composite strip 104 is disposed on a previous layer of the composite strip 104.

The device 100 also includes a backplane 106. The backing plate 106 is coupled to the tape placement machine 102. The back plate 106 is selectively positioned and/or selectively oriented (also referred to herein as selectively positioned) relative to the tape placement machine 102 to act as a placement surface 222. In other words, the backing plate 106 is configured to move relative to the tape placement machine 102 such that the tape placement machine 102 arranges the composite tape 104 on the backing plate 106. With the back plate 106 selectively positioned for use as the placement surface 222, the tape placement machine 102 is selectively positioned relative to the back plate 106. In other words, the tape placement machine 102 is configured to move relative to the backing plate 106 when the composite tape 104 is arranged.

Referring to fig. 6, when the back plate 106 is used as the placement surface 222, the back plate 106 is configured to react to the placement force 112 applied by the tape placement machine 102 when the composite tape 104 is being placed (e.g., placed or laid) on the back plate 106. In other words, the back plate 106 provides a reaction force 224 that is equal and opposite to the placement force 112. In an example, the apparatus 100 includes a reaction structure 226 that couples the back plate 106 and the tape placement machine 102 together and thereby forms a closed force reaction system. Stated differently, when the composite tape 104 is laid out, the placement force 112 is applied to the backing plate 106 and reacted by the backing plate 106 through the reaction structure 226 and back into the tape placement machine 102.

For the purposes of this disclosure, the term "placement force" refers to a force or load exerted by the tape placement machine 102 on the composite tape 104 and the placement surface 222 sufficient to sufficiently compress or compact the composite tape 104 on the placement surface 222 as the tape placement machine 102 places the composite tape 104. Generally, the placement force 112 applied by the tape placement machine 102 is directed toward the placement surface 222 (e.g., in a direction approximately perpendicular to the relative position on the placement surface 222). For purposes of this disclosure, the term "reacting to" … … and similar terms (e.g., reacting to the placement force 112 with reference to the backing plate 106) refer to providing a reaction force 224 that acts in an opposite direction on the placement force 112. Thus, for the purposes of this disclosure, the term "reaction force" refers to a force exerted by the placement surface 222 on the composite tape 104 and the tape placement machine 102 that is equal and opposite to the placement force 112.

The tape placement machine 102 may take the form of any suitable machine, apparatus, or device configured to manipulate the composite tape 104 and accurately place the composite tape 104 on a placement surface along a computer programmed placement path or route. The tape placement machine 102 is configured to lay down the composite tape 104 in various configurations corresponding to the selected placement surface 222 to thereby form one or more portions of the composite structure 300 into a desired shape. In one example, the tape placement machine 102 is a commercial automatic tape laying machine configured to accept composite tape having various widths. In one example, the tape placement machine 102 is an automatic tape lay-up machine (ATLM). In one example, the tape placement machine 102 is a Flat Tape Laying Machine (FTLM). In one example, the tape placement machine 102 is a Contour Tape Laying Machine (CTLM).

In one example, the tape placement machine 102 includes a delivery head 114, also referred to as a tape placement head. Delivery head 114 is configured or used to arrange (e.g., place or lay down) composite tape 104 in a configuration corresponding to a desired energy shape of composite structure 300. In an example, the backing plate 106 is coupled to the delivery head 114 and is selectively positioned relative to the delivery head 114 to react the placement force 112 applied by the delivery head 114 when the composite tape 104 is being disposed. In an example, reaction structure 226 couples backing plate 106 and delivery head 114 together to form a closed force reaction system.

Fig. 7 schematically illustrates an example embodiment of a method for forming a portion (e.g., first portion 358) of a composite structure 300 using the disclosed apparatus 100. Fig. 8 schematically illustrates an example embodiment of a method of forming another portion (e.g., second portion 360) of composite structure 300 using the disclosed apparatus 100. In an example, as illustrated in fig. 7, the device 100 is configured to form a first portion 358 of the composite structure 300 on the mandrel 116. In an example, as illustrated in fig. 8, device 100 is also configured to form second portion 360 of composite structure 300 on backplane 106.

In an example, the mandrel 116 is a tool having a tool surface 118, the tool surface 118 having a shape imparted to the composite strip 104 and thereby to at least a portion (e.g., the first portion 358) of the composite structure 300. In an example, as illustrated in fig. 7, the tool surface 118 is a contoured surface. In an example, as illustrated in fig. 8, the tool surface 118 is a flat surface. It should be appreciated that various types of mandrels may be used, and that the mandrel 116 may have a variety of shapes and/or sizes, and may define a variety of profiles.

Referring to fig. 7, in an example, the mandrel 116, and more specifically the tool surface 118 of the mandrel 116, serves as a placement surface 222 for placing the composite tape 104 to form a first portion 358 of the composite structure 300 using the tape placement machine 102. In an example implementation of the first part of the method for using the apparatus 100, the delivery head 114 is selectively positioned relative to the mandrel 116 such that the delivery head 114 contacts the mandrel 116 to place the composite strip 104 on the tool surface 118.

While the composite strip 104 is generally described herein as being disposed "on" the mandrel 116, it should be appreciated that the first layer 228 of the composite strip 104 is disposed directly on the mandrel 116, the second layer 232 is disposed on the first layer 228 of the composite strip 104, the third layer 230 of the composite strip 104 is disposed on the second layer 232 of the composite strip 104, and so on. In other words, each subsequent layer of the composite strip 104 is disposed on a previous layer of the composite strip 104.

In an example, when arranging the composite strip 104 on the mandrel 116, the delivery head 114 is moved linearly along one or more axes of a three-axis coordinate system and/or rotationally oriented about one or more axes of a three-axis coordinate system, for example, relative to the environmental reference system 340 of the manufacturing environment 368. In other words, the delivery head 114 is moved linearly and/or rotationally relative to the mandrel 116 to determine the position of the delivery head 114 in contact with the tool surface 118 (e.g., when the placement surface 222 is defined by the mandrel 116) and to dispose the composite tape 104 on the mandrel 116.

For purposes of this disclosure, the environmental reference frame 340 refers to a reference coordinate frame defined with respect to the manufacturing environment 368. In one example, the environmental reference frame 340 is a three-dimensional Cartesian coordinate system defined by an X-axis, a Y-axis, and a Z-axis. It should be appreciated that the Y-axis of the environmental reference frame 340 appears as a dot in fig. 7-9 and 17-30.

When delivery head 114 is disposing composite tape 104 on mandrel 116, backing plate 106 is selectively positioned relative to delivery head 114 and mandrel 116 such that backing plate 106 does not interfere with or otherwise interfere with the placement of composite tape 104 on mandrel 116.

Once the delivery head 114 is in contact with the mandrel 116, the delivery head 114 is configured to move relative to the mandrel 116 to dispose the composite tape 104 on the tool surface 118 in a predetermined configuration or lay-up. In an example, the delivery head 114 moves along a programmed placement path indicated by directional arrow 110 to lay each layer of the composite tape 104 on the mandrel 116.

Generally, delivery head 114 is moved substantially linearly along tool surface 118 (e.g., placement surface 222) of mandrel 116 following a placement path indicated by directional arrow 110. In an example, the delivery head 114 is moved along the tool surface 118 of the mandrel 116 in multiple passes, with layers of the composite tape 104 being placed in each pass to form one or more portions of the composite structure 300.

In an example, as illustrated in fig. 7, delivery head 114 moves along a placement path indicated by directional arrow 110 from a first mandrel position 152 (e.g., a beginning position of the placement path) on mandrel 116 to a second mandrel position 154 (e.g., an ending position of the placement path) on mandrel 116 opposite first mandrel position 152 to arrange first layer 228 of composite tape 104. Delivery head 114 then returns to first mandrel location 152 to begin another pass. As described in more detail herein, in some examples, delivery head 114 may be rotated at least partially, e.g., about the Z-axis of environmental reference frame 340, during one or more passes to lay down composite strip 104 in other directions. Thus, the orientation of the reinforcing fibers of the composite tape 104 forming the plies or layers of the composite structure 300 may vary from ply to ply (e.g., from +/-90 degrees, +/-45 degrees orientation, etc.). Delivery head 114 moves from first mandrel location 152 to second mandrel location 154 along a placement path indicated by directional arrow 110 to dispose second layer 232 of composite strip 104 in the same direction as first layer 228. This operation is repeated to arrange any additional layers (e.g., third layer 230, fourth layer, fifth layer, etc.) of composite strip 104.

Referring to fig. 8, in an example, delivery head 114 and backing plate 106 are selectively positioned relative to each other and mandrel 116 such that backing plate 106 provides or serves as placement surface 222 for arranging composite tape 104 to form second portion 360 of composite structure 300 using tape placement machine 102. In an example implementation of the second part of the method for using apparatus 100, delivery head 114 is selectively positioned relative to mandrel 116 and back plate 106, and back plate 106 is selectively positioned relative to delivery head 114 and mandrel 116 such that delivery head 114 is in contact with back plate 106 to place composite tape 104 on plate surface 146. In other words, delivery head 114, and thus the layers of composite tape 104, are rotated about the Y-axis of environmental reference 340 to lay composite tape 104 on backing sheet 106.

Although composite tape 104 is generally described herein as being disposed "on" backsheet 106, it should be appreciated that first layer 228 of composite tape 104 is disposed directly on backsheet 106, second layer 232 is disposed on first layer 228 of composite tape 104, third layer 230 of composite tape 104 is disposed on second layer 232 of composite tape 104, and so on. In other words, each subsequent layer of the composite strip 104 is disposed on a previous layer of the composite strip 104.

In an example, the backing plate 106 is a tool, such as a mandrel, having a plate surface 146, the plate surface 146 having a shape imparted to the composite tape 104 and thereby to at least a portion (e.g., the second portion 360) of the composite structure 300. In other words, the plate surface 146 of the back plate 106 serves as a placement surface 222 for placing the composite tape 104. In an example, the plate surface 146 is a flat surface. In an example, the plate surface 146 is a contoured surface. It should be appreciated that various types of plate members may be used, and that backing plate 106 may have a variety of shapes and/or sizes, and may define a variety of contours. Generally, the shape of the backing plate 106 is compatible with the formation of a portion (e.g., the second portion 360) of the composite structure 300 that protrudes from the tool surface 118 of the mandrel 116 or otherwise stands up against another portion (e.g., the first portion 358) of the composite structure 300.

In an example, when composite tape 104 is disposed on backing plate 106, each of delivery head 114 and backing plate 106 is moved linearly along and/or rotationally oriented about one or more axes of a three-axis coordinate system, for example, relative to environmental reference frame 340 of manufacturing environment 368. In other words, one or both of delivery head 114 and/or backing plate 106 are moved linearly and/or rotationally relative to backing plate 106 and relative to each other to determine the position of delivery head 114 in contact with plate surface 146 (e.g., when placement surface 222 is defined by backing plate 106) and to dispose composite tape 104 on backing plate 106.

When composite tape 104 is disposed on backing plate 106 using delivery head 114, backing plate 106 does not move relative to composite tape 104 being placed (the position and/or orientation of backing plate 106 does not change). Delivery head 114 moves relative to backing plate 106 as composite tape 104 is being placed on backing plate 106 using delivery head 114.

In the illustrated example, the backing plate 106 is selectively moved linearly and/or rotationally to a position adjacent to (e.g., at or near) the tool surface 118 of the mandrel 116 and an orientation approximately orthogonal to the relative position on the tool surface 118 of the mandrel 116. In other words, the back plate 106 is positioned such that the plate surface 146 acts as a continuation of the placement surface 222 from the tool surface 118. Delivery head 114 is selectively moved rotationally (e.g., approximately 90 degrees) and/or linearly (e.g., toward backing plate 106) to position delivery head 114 in contact with backing plate 106 to continue to dispose composite tape 104 on backing plate 106 from mandrel 116.

Once delivery head 114 is in contact with backing plate 106, delivery head 114 is configured to move relative to mandrel 116 and relative to backing plate 106 to dispose composite tape 104 on plate surface 146 in a predetermined configuration or lay-up. In an example, delivery head 114 moves along a programmed placement path indicated by directional arrow 234 to lay each layer of composite tape 104 on backing plate 106.

When delivery head 114 is disposing composite tape 104 on backing plate 106 (i.e., during placement of composite tape 104), the position of backing plate 106 relative to environmental reference frame 340 is fixed. In other words, the backing plate 106 acts as a force reaction support for the securement of the composite strip 104, and thus reacts the placement force 112 (fig. 5 and 6) applied to the composite strip 104 by the delivery head 114 by transferring the placement force 112 from the backing plate 106 and back to the delivery head 114 through the reaction structure 226.

In general, delivery head 114 is moved (e.g., tilted) generally rotationally, e.g., about the Y-axis of environmental reference 340, to transition from the programmed placement path indicated by directional arrow 110 (FIG. 7) to the programmed placement path indicated by directional arrow 234 (FIG. 8). Delivery head 114 is then moved substantially linearly along plate surface 146 of back plate 106 (e.g., placement surface 222) following a programmed placement path indicated by directional arrow 234 to lay composite tape 104 in a plane on plate surface 146 of back plate 106. In an example, delivery head 114 is moved in multiple passes along plate surface 146 of backing plate 106, with layers of composite tape 104 being placed in each pass to form one or more portions of composite structure 300.

In an example, as illustrated in fig. 8, delivery head 114 moves along a placement path indicated by directional arrow 234 from a first plate position 156 (e.g., a start position of the placement path) on back plate 106 to a second plate position 158 (e.g., a stop position of the placement path) on back plate 106 opposite first plate position 156 to arrange first layer 228 of composite tape 104. Delivery head 114 then returns to first plate position 156 to begin another pass. In an example, the delivery head 114 again moves from the first plate position 156 to the second plate position 158 along the placement path indicated by the direction arrow 234 to arrange the second layer 232 of the composite tape 104 in the same direction and therefore the same fiber orientation as the first layer 228. In an example, delivery head 114 moves along a different placement path (not illustrated in fig. 8) that is oriented in a different direction than the placement path indicated by directional arrow 234, e.g., by partially rotating delivery head 114 about the X-axis of environmental reference 340 to arrange second layer 232 of composite tape 104 in a different direction and therefore a different fiber orientation than first layer 228. This operation is repeated to arrange any additional layers (e.g., third layer 230, fourth layer, fifth layer, etc.) of composite strip 104.

Thus, in an example embodiment of a method for forming a composite structure 300 using the apparatus 100, as illustrated in the combination of fig. 7 and 8, the delivery head 114 is selectively moved linearly relative to the mandrel 116 from the first mandrel position 152 to the second mandrel position 154 along a first placement path indicated by directional arrow 110 (fig. 7), e.g., along the X-axis of the environmental reference frame 340, to dispose a first portion of the first layer 228 of the composite strip 104 on the mandrel 116 and partially form a first portion 358 of the composite structure 300. Backing plate 106 is then selectively moved relative to delivery head 114 and mandrel 116, for example rotationally about the Y-axis of environmental reference frame 340 and/or linearly along the Z-axis of environmental reference frame 340, such that plate surface 146 acts as a continuation of placement surface 222 and a second portion of first layer 228 of composite tape 104 can be disposed on plate surface 146. Delivery head 114 is then selectively rotationally moved relative to mandrel 116, e.g., about the Y-axis of environmental reference 340, such that delivery head 114 transitions from a first placement path indicated by directional arrow 110 to a second placement path indicated by directional arrow 234 (fig. 8). Delivery head 114 is then selectively moved linearly relative to back plate 106 from first plate position 156 to second plate position 158 along a second placement path indicated by directional arrow 234, e.g., along the Z-axis of environmental reference frame 340, to dispose a second portion of first layer 228 of composite tape 104 on back plate 106 and partially form second portion 360 of composite structure 300. Further, selective rotational movement of delivery head 114 about the Z-axis of environmental reference frame 340, such as when placing composite tape 104 on mandrel 116 or about the X-axis of environmental reference frame 340 when placing composite tape 104 on backing plate 106, enables laying of composite tape 104 in either a +45 degree orientation or a-45 degree orientation or a 90 degree orientation. Delivery head 114 then returns to first mandrel location 152 to begin another pass. Delivery head 114 is then selectively moved linearly relative to mandrel 116 from first mandrel position 152 to second mandrel position 154 along a first placement path indicated by directional arrow 110 (fig. 7), for example, along the X-axis of environmental reference frame 340, to dispose a first portion of second layer 232 of composite strip 104 on a first portion of first layer 228 of composite strip 104, and further form a first portion 358 of composite structure 300. Backing plate 106 is then selectively moved rotationally relative to delivery head 114 and mandrel 116, for example about the Y-axis of environmental reference frame 340 and/or linearly along the Z-axis of environmental reference frame 340, such that plate surface 146 is in surface contact with a second portion of first layer 228 opposite delivery head 114 to support the second portion of first layer 228 and enable a second portion of second layer 232 of composite tape 104 to be disposed on the second portion of first layer 228 of composite tape 104 supported from behind by plate surface 146. Delivery head 114 is then selectively rotationally moved relative to mandrel 116, e.g., about the Y-axis of environmental reference 340, such that delivery head 114 transitions from a first placement path indicated by directional arrow 110 to a second placement path indicated by directional arrow 234. Delivery head 114 then proceeds to selectively move linearly relative to back plate 106 from first plate position 156 to second plate position 158 along a second placement path indicated by directional arrow 234, e.g., along the Z-axis of environmental reference frame 340, to dispose a second portion of the second portion of composite tape 104 on a second portion of first layer 228 of composite tape 104 and further form second portion 360 of composite structure 300. Further, selective rotational movement of delivery head 114 about the Z-axis of environmental reference frame 340, e.g., when placing composite tape 104 on mandrel 116 or about the X-axis of environmental reference frame 340 when placing composite tape 104 on backing plate 106, enables composite tape 104 to be laid down in either a +45 degree orientation or a-45 degree orientation or a 90 degree orientation. This operation is repeated to arrange any additional layers (e.g., third layer 230, fourth layer, fifth layer, etc.) of composite strip 104.

In some examples, the composite tape 104 has sufficient tack or tackiness such that when the first layer 228 of the composite tape 104 is disposed on the tool surface 118 of the mandrel 116 and compacted by the compaction roller 124, the composite tape 104 adheres to the tool surface 118. When delivery head 114 transitions from disposing composite tape 104 on mandrel 116 to disposing composite tape 104 on backing plate 106 (e.g., transitions from a first placement path indicated by directional arrow 110 to a second placement path indicated by directional arrow 234), a sufficient length of composite tape 104 is fed from delivery head 114 so as not to lift or otherwise pull a first portion of first layer 228 of composite tape 104 from tool surface 118.

In the illustrative example, the second placement path indicated by directional arrow 234 is approximately perpendicular to the first placement path indicated by directional arrow 110 such that a second portion 360 of composite structure 300 extends from first portion 358 of composite structure 300 and is formed approximately perpendicular to first portion 358 of composite structure 300.

Still referring to fig. 7 and 8, in an example, the apparatus 100 includes a supply of one or more composite tapes 104 dispensed by the delivery head 114 and disposed on a placement surface 222, such as the tool surface 118 (fig. 7) of the mandrel 116 or the plate surface 146 (fig. 8) of the backing plate 106. In one example, the composite tape 104 is supplied in a dispenser 148. In one example, the dispenser 148 includes a roll 120 of composite tape 104, the roll 120 being supported on a spool 122, the spool 122 being mounted to the tape placer 102. In the illustrative example, dispenser 148 is mounted to or located in delivery head 114. In other examples, dispenser 148 may be located remotely from delivery head 114.

In some examples, the dispenser 148 includes a plurality of rollers 120 of the composite tape 104 or other supply that provides a plurality of composite tapes 104 to be simultaneously disposed on the placement surface 222 by the delivery head 114 and operated in parallel to form a portion of a ply or layer of the composite structure 300. Alternatively, the single composite strip 104 may be arranged in one or more sections. For example, a single composite strip 104 may be cut into multiple portions that are successively disposed on the placement surface 222, or a single composite strip 104 may be continuously disposed as a single piece on the placement surface without being severed. That is, reference herein to "a plurality of composite strips" may be arranged as a single piece of composite strip defining a plurality of adjacent elongate portions.

In an example, a spool 122 supporting a roller 120 of the composite tape 104 is rotatably mounted such that the composite tape 104 can be dispensed from the roller 120. From the roll 120, the composite tape 104 is fed to a placement guide 150, which placement guide 150 controls placement of the composite tape 104 on a placement surface (e.g., the tool surface 118 or the board surface 146).

In an example, the placement guide 150 includes one or more compaction rollers 124, the one or more compaction rollers 124 being rotationally mounted to the delivery head 114 such that the delivery head 114 can be moved over the placement surface 222 with the compaction rollers 124 in rolling contact therewith. As illustrated in fig. 2, the apparatus 100 applies a placement force 112 on the placement surface 222 through the compaction roller 124 via the delivery head 114. The placement force 112 is generally applied toward the placement surface 222, e.g., the placement force 112 is approximately normal to the placement surface 222, such that the compaction roller 124 applies the placement force 112 (e.g., compaction pressure) on the composite strip 104 to press it against the placement surface 222. The apparatus 100 reacts the placement force 112 back to the delivery head 114 via the backing plate 106 through the reaction structure 226 such that the reaction force 224 exerted on the compaction roller 124 counteracts the placement force 112 (e.g., the sum of the forces is zero).

In one example, compaction roller 124 is adjustably mounted to delivery head 114 by one or more roller mounts 128. The roller mount 128 adjusts the position of the compaction roller 124 relative to the rest of the delivery head 114 such that the compaction roller 124 can apply varying pressure on the composite tape 104 and the placement surface 222 (e.g., the mandrel 116 or the backing plate 106) or otherwise control the placement of the composite tape 104. In an example, the application of the placement force 112 is applied by the compaction roller 124 via a roller mount 128. Although the illustrative example of the placement guide 150 includes a compaction roller 124, in other examples, the placement guide 150 may include other types of compaction devices, such as a compacted block or a press.

In an example, the device 100 also includes a mobile system 130. The movement system 130 is configured to position the tape placement machine 102 when placing the composite tape 104. More specifically, movement system 130 is configured to move delivery head 114 relative to placement surface 222 to achieve a desired relative position of delivery head 114 with respect to placement surface 222 for disposing composite tape 104. In an example, as illustrated in fig. 7, the movement system 130 moves the delivery head 114 relative to the mandrel 116 to achieve a desired position, location, and/or orientation of the delivery head 114 relative to the tool surface 118 for placing the composite tape 104 on the mandrel 116. In an example, as illustrated in fig. 8, movement system 130 moves delivery head 114 relative to back sheet 106 to achieve a desired position, orientation, and/or orientation of delivery head 114 relative to a sheet surface 146 used to place composite tape 104 on back sheet 106.

The movement system 130 may include various drive devices, such as pneumatic or hydraulic actuators, electric motors or servos, and/or chain, gear, or shaft drive mechanisms. In an example, the movement system 130 includes or takes the form of a robot 236 (fig. 5) or other robotic arm configured to move the tape placement machine 102, or at least the delivery head 114, about multiple axes relative to the placement surface. In an example, the robot 236 includes a base, one or more arms, and one or more actuators (e.g., servo motors) operable to move each arm. It should be noted that robot 236 may include a greater or lesser number of arms and/or different types of members such that any desired range of rotation and/or translation of delivery head 114 may be provided. In other examples, movement system 130 may include a gantry robot or other suitable type of movement assembly.

In some examples, the tape placement machine 102 may also include various other components. In an example, the placement guide 150 includes one or more guide rollers 126, the one or more guide rollers 126 being rotationally mounted to the delivery head 114 to guide the composite tape 104 along or through the delivery head 114. Any number of guide rollers 126 may be provided, and in some examples, some or all of the guide rollers 126 may be driven by a motor or other actuator to control the movement of the composite tape 104.

In one example, the tape placement machine 102 includes a heater 136 for heating the composite tape 104. In some examples, the heater 136 is a laser, a laser diode array, a hot gas torch (hot gas torch), an electric heater, an infrared heater, or another type of suitable heating device. The heater 136 typically delivers sufficient energy to allow the composite tape 104 to adhere to the underlying composite tape 104 once subjected to a compaction force (i.e., the placement force 112) applied, for example, by the compaction roller 124. In other words, the composite tape 104 is heated sufficiently to promote the desired bonding of the composite tape 104 to the surface to which it is applied.

The heater 136 may include a plurality of individual heating elements, such as in an array. Each heating element may be coupled to a power source independently of the other laser elements such that the operating power of each heating element can be controlled independently of the other heating elements. Further, the individual heating elements may be arranged such that each is configured to heat a particular region or zone definable by the composite tape 104 before and/or after being placed on the surface. Thus, by varying the operating power of one or more of the heating elements, the heating of a particular composite strip in the composite strip 104 or a particular region of the composite strip 104 can be controlled independently of the heating of other composite strips 104. For example, if the composite strips 104 are not the same size or made of the same material and therefore require different amounts of energy to reach their optimal temperature for placement, non-uniform heating of the zones may be desirable.

In one example, the tape placement machine 102 includes an inspection system 138. In one example, the inspection system 138 includes a camera for monitoring the composite tape 104, a temperature sensor, a pre-placement detector, an adhesion monitoring device, and the like. In an example, the tape placement machine 102 may include a marking device for marking a flaw or other designated portion of the composite tape 104. In an example, the tape placement machine 102 may include a detector, such as a camera or photo eye (photo eye), configured to detect the contour and position of the composite tape 104 on the placement surface to verify that the composite tape 104 is properly configured with minimal gaps and overlap, for example.

In one example, the tape placement machine 102 includes a conditioner 140. The trimmer 140 is configured to trim, cut, trim, or otherwise cut the composite strip 104 to a desired length and/or configuration. In one example, the dresser 140 is located near the nip of the compaction roller 124. For purposes of this disclosure, the "nip" of the compaction roller 124 refers to the location where the placement force 112 on the compaction roller 124 is applied to the placement surface 222. Positioning the conditioner 140 proximate the nip of the compaction roller 124 can eliminate an uncontrolled length of the composite strip 104 after the composite strip 104 is cut.

In an example, the trimmer 140 includes a mechanical cutting device, such as a blade 142 defining a sharp edge. The conditioner 140 may further include a reciprocating actuator 144 for moving the blades 142 in alternating directions, e.g., generally perpendicular to the plane of the composite strip 104, such that the edges of the blades 142 can be used to smoothly cut through the composite strip 104. In other examples, the trimmer 140 may include other cutting devices, such as rollers defining a sharp circumferential edge, stationary blades, lasers, and the like. In any example, the actuator 144 may also be configured to move the blade 142 or other cutting device in a direction transverse to the length of the composite tape 104 to adjust the amount of the composite tape 104 to be trimmed. In some examples, the actuator 144 may be configured to adjust the angle of the blade 142 relative to the composite strip 104, e.g., to optimize the cutting operation of the blade 142. In some examples, one or more collector devices may be provided for receiving a trimmed portion of the composite strip 104 that may be discarded or reused.

In an example, the apparatus 100 includes a controller 132. The controller 132 is configured to control the function and/or operation of one or more components of the apparatus 100. In an example, the controller 132 is communicatively (e.g., electrically) coupled with one or more of the placement guide 150, the heater 136, the conditioner 140, and the inspection system 138 to control operation thereof. In one example, controller 132 is configured to selectively control the position of back plate 106 relative to delivery head 114. In some examples, controller 132 is located within delivery head 114. In some examples, controller 132 is located remotely from delivery head 114.

In some examples, controller 132 is communicatively coupled with movement system 130 to control movement of delivery head 114 relative to placement surface 222 along a programmed placement path as composite strip 104 is arranged. In some examples, the device 100 may include one or more additional controllers configured to control the operation of the mobile system 130.

In some examples, the apparatus 100 may include a computer system 238 (e.g., one or more computers) configured to perform instructions that control the control operations of the tape placement machine 102 and/or the movement of the delivery head 114 along the programmed path when arranging the composite tape 104. In an example, the controller 132 and any additional control may be implemented at least in part by the computer system 238.

In some examples, the controller 132 and/or the computer system 238 may be operable to perform other functions, such as inspection of the composite tape 104 after it is disposed on the placement surface 222, control of the placement speed of the composite tape 104, detection of the temperature of the composite tape 104, marking of detected defects of the composite tape 104, and so forth.

In an example, the configuration of the placement path of delivery head 114 may be determined before some or all of composite tape 104 is disposed on placement surface 222. In an example, the method for determining the configuration of the placement path may be performed theoretically or digitally, and then the composite tape 104 may be arranged accordingly. In an example, the computed configuration of the placement path is electronically stored in the memory 134 of the device 100. The apparatus 100 then arranges the composite tape 104 according to the configuration of the calculated respective placement paths.

In an example, the composite strip 104 includes a reinforcement material disposed in a matrix material. The composite tape 104 may be provided in various sizes and/or shapes. In one example, the composite tape 104 is a continuous composite tape. Generally, as used herein, the term "continuous" refers to an article that is uninterrupted or has a length dimension that is several orders of magnitude greater than a width dimension. In one example, the composite tape 104 takes the form of a long rectangular tape having a width between about 0.5 inches (1.27 centimeters) and about 12 inches (30.48 centimeters).

In various examples, the reinforcing material of the composite tape 104 includes a plurality of fibrous members, such as fibers, strands, braids, such as fiberglass, metals, minerals, conductive or non-conductive graphite or carbon, nylon, aramid (such as

) Etc. of a woven or non-woven mat of material. In some examples, the composite tape 104 is unidirectional fiber reinforced (e.g., includes unidirectional reinforcement material). In various examples, the composite tape 104 includes a matrix material in which the reinforcement material is disposed. In some examples, however, the composite tape 104 can be formed without a matrix material, and the matrix material can be separately arranged. In any example, the matrix material may include various materials, such as a thermoplastic or a thermoset polymer resin. Exemplary thermosetting resins include allyl compounds, alkyd polyesters, Bismaleimides (BMIs), epoxy resins, phenolic resins, polyesters, Polyurethanes (PURs), polyureaformaldehydes, cyanoesters, and vinyl ester based resins. Exemplary thermoplastic resins include Liquid Crystal Polymers (LCP); fluoroplastics including Polytetrafluoroethylene (PTFE), Fluorinated Ethylene Propylene (FEP), perfluoroalkoxy resin (PFA), Polychlorotrifluoroethylene (PCTFE), and polytetrafluoroethylene-perfluoromethylvinylether (MFA); ketone based resins, including Polyetheretherketone (PEEK)^TMVictrex PLC Corporation (trademarks of Thointons Cleveley Lancashire, UK); polyamides such as nylon-6/6, 30% glass fiber; polyethersulfone (PES), imide (PAIS), Polyethylene (PE); polyester thermoplastics including polybutylene terephthalate (PBT), polyethylene tetraphenyl terephthalate (PET), and poly (m-phenylene terephthalate); polysulfone (PSU); polyphenylene Sulfide (PPS).

Referring to fig. 9, in some examples, the radius of curvature of the transition 364 forming the composite stiffener 308 is defined by or dependent on the radius of the compaction roller 124. The compaction roller 124 is selected (e.g., sized) such that a radius of the compaction roller 124 is substantially equal to a radius of the transition 364 of the composite stiffener 308. In other words, the radius of the compaction roller 124 is equal to the radius of the arcuate transition between the portion of the flange 332 and the portion of the web 328 formed by the outermost layer of the composite strip 104 forming the composite stiffener 308. For example, as illustrated in fig. 9, the radius of the compaction roller 124 is less than the radius of the arcuate transition between the flange 332 and the web 328 formed by the first layer 228 (i.e., the innermost layer) of the composite strip 104. The radius of the compaction roller 124 is also less than the radius of the arcuate transition between the flange 332 and the web 328 formed by the second layer 232 (i.e., the intermediate layer) of the composite strip 104. The radius of the compaction roller 124 is substantially equal to the radius of the arcuate transition between the flange 332 and the web 328 formed by the third layer 230 (i.e., the outermost layer) of the composite strip 104.

Referring to fig. 2-4 and 9, in some examples, the composite structure 300 includes a radius filler 338, also commonly referred to as a facing/filler (noodle). Radius filler 338 is configured to support transition 364 between flange 332 and web 328 of composite stiffener 308 when composite tape 104 is disposed by delivery head 114. In some examples, as illustrated in fig. 2 and 4, the radius filler 338 is located within a small space formed between the composite stiffener 308 and the composite panel 302 at the base or root of the web 328 of the composite stiffener 308. In some examples, as illustrated in fig. 3 and 9, the radius filler 338 is partially located between the composite stiffener 308 and the composite panel 302 at the base of the web 328 of the composite stiffener 308.

In an example, radius fillers 338 are placed on the inner surface 330 of the composite panel 302 prior to lay-up of the plies 334 of the composite tape 104 to form the composite stiffener 308. In one example, the radius filler 338 includes a generally rectangular shape and may be various materials, such as carbon fiber (e.g., woven or non-woven) and resin materials. The shape and material of the radius filler 338 is selected to fill the space between the composite stiffener 308 and the composite panel 302 at the base of the web 328 and to bond to the composite material of the composite stiffener 308 and the composite panel 302. Depending on the material of the radius filler 338, the radius filler 338 may also transfer loads between adjacent portions between the composite stiffener 308 and the composite panel 302.

Fig. 10 schematically illustrates a portion of a composite structure 300 formed using an example of the disclosed apparatus 100. The apparatus 100 is not illustrated in fig. 10 in order to more clearly illustrate the various movements or placements, the paths followed by the delivery head 114, and the lay-up configuration of the composite tape 104 forming the composite structure 300.

In some examples, composite stiffener 308 includes a longitudinal axis 324 and has a length dimension parallel to or running with longitudinal axis 324, a width dimension transverse to longitudinal axis 324, and a height dimension transverse to longitudinal axis 324. Further, each of the flange 332 and the web 328 has a thickness dimension. In one example, the flange 332 and the web 328 define a width dimension of the composite stiffener 308. The flange 332 and the web 328 also define the height dimension of the composite stiffener 308. Throughout the present disclosure, and as illustrated in fig. 6-10 and 17-32, the longitudinal axis 324 of the composite stiffener 308 is parallel to the Y-axis of the environmental reference frame 340.

To create a composite reinforcement 308 having a desired length dimension, multiple layers of the composite strip 104 are arranged adjacent to one another (e.g., side-by-side). To create a composite stiffener 308 having a desired height dimension and a flange 332 and web 328 having a desired corresponding thickness dimension, multiple layers of composite tape 104 are arranged one on top of the other (e.g., stacked on top of each other).

In an example, when composite stiffener 308 is initially formed on composite panel 302, delivery head 114 (not illustrated in fig. 10) is selectively positioned at first indexing location 248, e.g., relative to composite panel 302 and/or environmental reference 340. Delivery head 114 is then selectively moved linearly along a first placement path indicated by directional arrow 110, e.g., along the X-axis of environmental reference frame 340, to dispose first continuous section 370 of composite strip 104 on composite panel 302, as illustrated in fig. 7, and form a flange portion of first flange layer 372 of flange 332 of composite stiffener 308. Delivery head 114 is then selectively moved, e.g., rotationally about the Y-axis of environmental reference frame 340, to dispose first continuous segment 370 of composite strip 104 over radius filler 338 and transition from the flange portion of first flange layer 372 of flange 332 to the web portion of first web layer 374 of web 328 of composite stiffener 308 and form a portion of transition 364 (fig. 2-4) of composite stiffener 308. Delivery head 114 is then selectively moved linearly along a second placement path indicated by directional arrow 234, e.g., along the Z-axis of environmental reference frame 340, to arrange first continuous segment 370 of composite strip 104 on back plate 106 (not illustrated in fig. 10), as illustrated in fig. 8, and form a web portion of first web layer 374 of web 328 of composite stiffener 308.

In some example configurations of composite stiffener 308, such as those illustrated in fig. 2 and 10 having an inverted "T" shaped cross-section, delivery head 114 is then selectively moved rotationally, e.g., about the Y-axis of environmental reference 340, to transition from the web portion of first web layer 374 to a supplemental web portion of first web layer 374 and form a portion of distal end 362 of web 328. Delivery head 114 is then selectively moved along a corresponding placement path (not visible in fig. 10), for example along the Z-axis of environmental reference frame 340, to dispose first continuous segment 370 of composite strip 104 on a web portion of first web layer 374 supported from behind by back plate 106 (not shown in fig. 10), and to form a supplemental web portion of first web layer 374 of web 328. Delivery head 114 is then selectively moved, e.g., rotationally about the Y-axis of environmental reference frame 340, to dispose first continuous segment 370 of composite strip 104 over radius filler 338 and transition from the supplemental web portion of first web layer 374 of web 328 to the supplemental flange portion of first flange layer 372 of flange 332 and form part of the supplemental transition of composite stiffener 308. Delivery head 114 is then selectively moved linearly along a corresponding placement path (not visible in fig. 10), e.g., along the X-axis of environmental reference frame 340, to dispose first continuous section 370 of composite strip 104 on composite panel 302 and form a flange portion of first flange layer 372 of flange 332 of composite stiffener 308. The first continuous segment 370 of the composite strip 104 is then cut to complete the corresponding portion of the composite stiffener 308.

In some example configurations of the composite stiffener 308, such as those illustrated in fig. 3 having an "L" shaped cross-section, the first continuous segment 370 of the composite strip 104 is cut after formation of the web portion of the first web layer 374 to complete the corresponding portion of the composite stiffener 308.

In some example configurations of composite stiffener 308, such as the blade-type stringer illustrated in fig. 4, delivery head 114 is then selectively moved as described above to further form a supplemental web portion of first web layer 374 of web 328 and a layer of composite panel 302. The first continuous segment 370 of the composite strip 104 is then cut to complete the corresponding portion of the composite stiffener 308.

Once the portions of first flange layer 372 and first web layer 374 formed by first continuous section 370 of composite band 104 have been arranged, delivery head 114 is selectively positioned to second indexing location 250. For example, delivery head 114 may return to first indexing position 248 and move linearly along an indexing path indicated by directional arrow 240 to second indexing position 250, e.g., along the Y-axis of environmental reference frame 340.

Delivery head 114 is then selectively moved linearly along a third placement path indicated by directional arrow 252, e.g., along the X-axis of environmental reference frame 340, to dispose a second continuous segment 376 of composite strip 104 on composite panel 302 adjacent (e.g., next to) first continuous segment 370 of composite strip 104 and further form a flange portion of first flange layer 372 of flange 332 of composite stiffener 308. Delivery head 114 is then selectively moved, e.g., rotationally about the Y-axis of environmental reference frame 340, to dispose a second continuous section 376 of composite strip 104 on radius filler 338 adjacent (e.g., next to) first continuous section 370 of composite strip 104 and transition from the flange portion of first flange layer 372 of flange 332 to the web portion of first web layer 374 of web 328 and form another portion of transition 364 (fig. 2-4) of composite reinforcement 308. Delivery head 114 is then selectively moved linearly along a fourth placement path indicated by directional arrow 254, e.g., along the Z-axis of environmental reference frame 340, to dispose a second continuous segment 376 of composite strip 104 on back plate 106 adjacent (e.g., next to) first continuous segment 370 of composite strip 104 and further form a web portion of first web layer 374 of web 328 of composite stiffener 308.

In some example configurations of composite stiffener 308, such as those having an inverted "T" shaped cross-section such as illustrated in fig. 2 and 10, delivery head 114 is then selectively moved as described above to further form a supplemental web portion of first web layer 374 of web 328 and a supplemental flange portion of first flange layer 372 of flange 332 with second continuous section 376 of composite band 104. The second continuous segment 376 of the composite strip 104 is then cut to complete the corresponding portion of the composite stiffener 308.

In some example configurations of the composite stiffener 308, such as those illustrated in fig. 3 having an "L" shaped cross-section, the second continuous segment 376 of the composite strip 104 is cut after formation of the web portion of the first web layer 374 to complete the corresponding portion of the composite stiffener 308.

In some example configurations of composite stiffener 308, such as the blade-type stringer illustrated in fig. 4, delivery head 114 is then selectively moved as described above to further form a supplemental web portion of first web layer 374 of web 328 and a layer of composite panel 302. The second continuous segment 376 of the composite strip 104 is then cut to complete the corresponding portion of the composite stiffener 308.

This process is repeated to form the first flange layer 372 of flange 332 and the additional portion of the first web layer 374 of web 328 by selectively linearly moving delivery head 114 along an indexing path indicated by directional arrow 240, e.g., along the Y-axis of environmental reference frame 340, to a subsequent indexing location and arranging a subsequent successive section of composite strip 104 adjacent to the previous section of composite strip 104. In an example, the indexing path indicated by directional arrow 240 is parallel to a longitudinal axis 324 of the composite stiffener 308.

Once first flange 372 and first web layer 374 and composite stiffener 308 are completed, delivery head 114 is selectively moved back to first indexing position 248. Delivery head 114 is then selectively moved linearly along a first placement path indicated by directional arrow 110, e.g., along the X-axis of environmental reference frame 340, to dispose third continuous section 378 of composite strip 104 on first continuous section 370 and form a flange portion of second flange layer 380 of flange 332 of composite stiffener 308. Delivery head 114 is then selectively moved, e.g., rotationally about the Y-axis of environmental reference frame 340, to dispose third continuous segment 378 of composite band 104 over first continuous segment 370 and transition from the flange portion of second flange layer 380 of flange 332 to the web portion of second web layer 382 of web 328 of composite stiffener 308 and form another portion of transition 364 (fig. 2-4) of composite stiffener 308. Delivery head 114 is then selectively moved linearly along a second placement path as indicated by directional arrow 234, e.g., along the Z-axis of environmental reference frame 340, to dispose third continuous segment 378 of composite strip 104 on first continuous segment 370 supported from behind by back plate 106 (not shown in fig. 9) and form a web portion of second web layer 382 of web 328 of composite stiffener 308.

In some example configurations of composite stiffener 308, such as those having an inverted "T" shaped cross-section such as illustrated in fig. 2 and 10, delivery head 114 is then selectively moved as described above to further form a supplemental web portion of second web layer 382 of web 328 and a supplemental flange portion of second flange layer 380 of flange 332 with third continuous section 378 of composite strip 104. The third continuous segment 378 of composite strip 104 is then cut to complete the corresponding portion of composite stiffener 308.

In some example configurations of composite stiffener 308, such as those illustrated in fig. 3 having an "L" shaped cross-section, third continuous segment 378 of composite strip 104 is cut after formation of the web portion of second web layer 382 to complete the corresponding portion of composite stiffener 308.

In some example configurations of composite stiffener 308, such as the blade-type stringer illustrated in fig. 4, delivery head 114 is then selectively moved as described above to further form a supplemental web portion of first web layer 374 of web 328 and a layer of composite panel 302. The third continuous segment 378 of composite strip 104 is then cut to complete the corresponding portion of composite stiffener 308.

Once the portions of second flange layer 380 and second web layer 382 formed from third continuous section 378 of composite strip 104 have been arranged, delivery head 114 is selectively positioned to second indexing location 250. For example, delivery head 114 may return to first indexing position 248 and move linearly along an indexing path indicated by directional arrow 240 to second indexing position 250, e.g., along the Y-axis of environmental reference frame 340. Delivery head 114 is then selectively moved linearly along a third placement path indicated by directional arrow 252, e.g., along the X-axis of environmental reference frame 340, to dispose a fourth continuous segment 384 of composite strip 104 adjacent (e.g., next to) third continuous segment 378 of composite strip 104 on second continuous segment 376 and further form a flange portion of second flange layer 380 of flange 332 of composite stiffener 308. Delivery head 114 is then selectively moved, e.g., rotationally about the Y-axis of environmental reference frame 340, to dispose fourth continuous section 384 of composite band 104 over second continuous section 376 and transition from the flange portion of second flange layer 380 of flange 332 to the web portion of second web layer 382 of web 328 and further form part of transition 364 (fig. 2-4) of composite stiffener 308. Delivery head 114 is then selectively moved linearly, e.g., along the Z-axis of environmental reference frame 340, along a fourth placement path indicated by directional arrow 254, delivery head 114 is then selectively moved linearly, e.g., along the Z-axis of environmental reference frame 340, along the fourth placement path indicated by directional arrow 254, to dispose a fourth continuous segment 384 of composite strip 104 adjacent (e.g., next to) third continuous segment 378 of composite strip 104 on second continuous segment 376, and further to form a web portion of second web layer 382 of web 328 of composite stiffener 308.

In some example configurations of composite stiffener 308, such as those having an inverted "T" shaped cross-section such as illustrated in fig. 2 and 10, delivery head 114 is then selectively moved as described above to further form a supplemental web portion of second web layer 382 of web 328 and a supplemental flange portion of second flange layer 380 of flange 332 with fourth continuous segment 384 of composite band 104. The fourth continuous segment 384 of the composite strip 104 is then cut to complete the corresponding portion of the composite reinforcement 308.

In some example configurations of the composite stiffener 308, such as those illustrated in fig. 3 having an "L" shaped cross-section, the fourth continuous segment 384 of the composite strip 104 is cut after formation of the web portion of the second web layer 382 to complete the corresponding portion of the composite stiffener 308.

In some example configurations of composite stiffener 308, such as the blade-type stringer illustrated in fig. 4, delivery head 114 is then selectively moved as described above to further form a supplemental web portion of first web layer 374 of web 328 and a layer of composite panel 302. The fourth continuous segment 384 of the composite strip 104 is then cut to complete the corresponding portion of the composite reinforcement 308.

This process is repeated to form second flange layer 380 of flange 332 and additional portions of second web layer 382 of web 328 by moving delivery head 114 along an indexing path indicated by directional arrow 240 to a subsequent indexing location and arranging a subsequent continuous section of composite tape 104 adjacent a previous continuous section of composite tape 104.

The process is also repeated to form additional flange layers on top of flange 332 and additional web layers of web 328 by moving delivery head 114 along the placement path in subsequent passes and disposing subsequent successive sections of composite strip 104 on top of previous successive sections of composite strip 104.

Fig. 11 and 12 schematically illustrate an example of an apparatus 100 in which a backing plate 106 is selectively moved into position relative to a delivery head 114 so that a composite tape 104 (not shown in fig. 11 and 12) can be disposed on a mandrel 116 (not shown in fig. 11 and 12), for example, as illustrated in fig. 7. Fig. 13 and 14 schematically illustrate an example of apparatus 100 in which backing plate 106 is selectively moved into position relative to delivery head 114 such that composite tape 104 (not shown in fig. 13 and 14) can be disposed on backing plate 106, e.g., as illustrated in fig. 8.

Referring to fig. 11-14, generally, delivery head 114 may be moved linearly and/or rotationally relative to environmental reference 340 to selectively position delivery head 114 relative to one of mandrel 116 or backing plate 106 and to dispose composite strip 104 on one of mandrel 116 or backing plate 106, e.g., to form first portion 358 of composite structure 300, as illustrated in fig. 7 and 8. Backing plate 106 may be moved linearly and/or rotationally relative to environmental reference 340 to selectively position backing plate 106 relative to delivery head 114 and mandrel 116, and to dispose composite tape 104 on backing plate 106, e.g., to form second portion 360 of composite structure 300, as illustrated in fig. 8.

In some examples, delivery head 114 includes a head reference frame 242. For purposes of this disclosure, head reference frame 242 refers to a reference coordinate frame defined with respect to points on delivery head 114 and rigid to delivery head 114. In one example, the head reference frame 242 is a three-dimensional Cartesian coordinate system defined by X-axis, Y-axis, and Z-axis. In an example, the placement path followed by delivery head 114 when laying out composite tape 104 is parallel to the X-axis of head reference frame 242. In one example, the axis of rotation of the compaction roller 124 is parallel to the Y-axis of the head reference frame 242.

In some examples, the back plate 106 includes a plate reference frame 244. For purposes of this disclosure, plate reference frame 244 refers to a reference coordinate frame defined with respect to points on back plate 106 and rigid to back plate 106. In one example, the plate reference frame 244 is a three-dimensional Cartesian coordinate system defined by an X-axis, a Y-axis, and a Z-axis.

In some examples, the apparatus 100 includes a first linear axis of motion 168. Backing plate 106 is linearly movable relative to delivery head 114 along a first linear axis of motion 168. In an example, the back plate 106 is linearly movable along the first linear motion axis 168 in a direction indicated by a first linear motion direction arrow 188. In an example, as illustrated in fig. 11 and 12, when back plate 106 is selectively positioned to enable delivery head 114 to dispose composite tape 104 on mandrel 116 (fig. 7), linear movement of back plate 106 along first linear axis of motion 168 moves back plate 106 toward and away from delivery head 114 such that back plate 106 does not interfere with or otherwise interfere with the placement of composite tape 104 on mandrel 116. In an example, as illustrated in fig. 13 and 14, when the backing plate 106 is selectively positioned to enable the delivery head 114 to dispose the composite tape 104 on the backing plate 106 (fig. 8), linear movement of the backing plate 106 along the first linear axis of motion 168 moves the backing plate 106 toward and away from the compaction roller 124 such that the backing plate 106 is in position to act as the placement surface 222 for disposing the composite tape 104 and react the placement force 112.

In one example, first linear axis of motion 168 passes through backing plate 106 and delivery head 114. In one example, the first linear axis of motion 168 is parallel to the X-axis of the plate reference frame 244. In an example, first linear axis of motion 168 is parallel to the Z-axis of head reference frame 242 (fig. 13 and 14) when delivery head 114 and backing plate 106 are selectively positioned relative to each other to dispose composite tape 104 on backing plate 106.

In an example, selective linear movement of back plate 106 along first linear axis of motion 168 selectively positions back plate 106 relative to delivery head 114 such that back plate 106 is in position for delivery head 114 to contact back plate 106, and plate surface 146 of back plate 106 acts as placement surface 222 for placing first layer 228 (fig. 8) of composite tape 104 on plate surface 146 to form a portion of first web layer 374 (fig. 10) of web 328. In an example, selective linear movement of back plate 106 along first linear axis of motion 168 selectively positions back plate 106 relative to first web layer 374 of web 328 such that back plate 106 is in position for delivery head 114 to contact first layer 228 (fig. 8) of composite tape 104, said first layer 228 serving as placement surface 222 for placing second layer 232 (fig. 8) of composite tape 104 on first layer 228 to form a portion of second web layer 382 (fig. 10) of web 328, and so on.

As described hereinabove, when composite tape 104 is laid out, delivery head 114 moves relative to environmental reference frame 340 and backing plate 106, and backing plate 106 may move relative to delivery head 114 but remain fixed relative to environmental reference frame 340. Thus, when composite tape 104 is disposed on backing plate 106, selective linear movement of backing plate 106 along first linear axis of motion 168 also coincides with linear movement of delivery head 114 relative to backing plate 106.

In one example, the apparatus 100 includes a first axis of rotational motion 162. Backing plate 106 is rotationally movable relative to delivery head 114 about a first rotational axis of motion 162. In an example, back plate 106 is rotationally movable about first rotational motion axis 162 in a direction indicated by first rotational motion direction arrow 194. For example, selective rotation of back plate 106 about first rotational axis of motion 162 orbitally rotates back plate 106 at least partially about delivery head 114 and more specifically at least partially about compaction roller 124. In an example, as illustrated in fig. 9 and 10, when backing plate 106 is selectively positioned to enable delivery head 114 to dispose composite tape 104 on mandrel 116 (fig. 7), rotational movement of backing plate 106 along first rotational axis of motion 162 moves backing plate 106 out of alignment with compaction roller 124. In an example, as illustrated in fig. 11 and 12, when the backing plate 106 is selectively positioned to enable the delivery head 114 to dispose the composite tape 104 on the backing plate 106 (fig. 8), rotational movement of the backing plate 106 along the first rotational axis of motion 162 moves the backing plate 106 into alignment with the compaction roller 124 such that the backing plate 106 is in position to act as a placement surface 222 for disposing the composite tape 104 and to react the placement force 112.

In one example, as illustrated in fig. 11, first rotational axis of motion 162 passes through delivery head 114. In an example, as illustrated in fig. 12, first rotational axis of motion 162 is located in the space between delivery head 114 and backing plate 106. In one example, the first rotational axis of motion 162 is parallel to the Y-axis of the head reference frame 242. In one example, the first linear axis of motion 168 intersects the first rotational axis of motion 162.

In some examples, as illustrated in fig. 11 and 12, selective rotational movement of back plate 106 about first rotational movement axis 162 selectively positions back plate 106 relative to delivery head 114 such that back plate 106 does not interfere with or otherwise interfere with the placement of composite tape 104 on mandrel 116 (fig. 6).

In some examples, as illustrated in fig. 13 and 14, selective rotational movement of back plate 106 about first rotational axis 162 selectively positions back plate 106 relative to delivery head 114 such that back plate 106 is in position for delivery head 114 to contact back plate 106, and plate surface 146 of back plate 106 acts as a portion of first web layer 374 (fig. 10) for placement of composite tape 104 (fig. 8) to form web 328. In an example, selective linear movement of back plate 106 along first rotational axis of motion 162 selectively positions back plate 106 relative to first web layer 374 of web 328 such that back plate 106 is in position for delivery head 114 to contact first layer 228 (fig. 8) of composite tape 104, which first layer 228 serves as placement surface 222 for placing second layer 232 (fig. 8) of composite tape 104 on first layer 228 to form a portion of second web layer 382 (fig. 10) of web 328, and so on.

As described hereinabove, when composite tape 104 is laid out, delivery head 114 moves relative to environmental reference frame 340 and backing plate 106, and backing plate 106 may move relative to delivery head 114 but remain fixed relative to environmental reference frame 340. Thus, when composite tape 104 is disposed on backing plate 106, selective rotational movement of backing plate 106 about first rotational axis of motion 162 also coincides with rotational movement of delivery head 114 relative to backing plate 106.

In one example, the apparatus 100 includes a second linear axis of motion 170. Backing plate 106 is linearly movable relative to delivery head 114 along a second linear axis of motion 170. In an example, back plate 106 is linearly movable along a second linear motion axis 170 in a direction indicated by a second linear motion direction arrow 190. In an example, as illustrated in fig. 9 and 10, when back plate 106 is selectively positioned to enable delivery head 114 to dispose composite tape 104 on mandrel 116 (fig. 7), linear movement of back plate 106 along second linear motion axis 170 moves back plate 106 such that back plate 106 does not interfere with or otherwise interfere with the placement of composite tape 104 on mandrel 116. In an example, as illustrated in fig. 13 and 14, when the back plate 106 is selectively positioned to enable the delivery head 114 to dispose the composite tape 104 on the back plate 106 (fig. 8), linear movement of the back plate 106 along the second linear axis of motion 170 moves the back plate 106 such that the back plate 106 is in position to act as the placement surface 222 for disposing the composite tape 104 and to react the placement force 112.

In one example, the second linear axis of motion 170 passes through the back plate 106. In one example, the second linear axis of motion 170 is parallel to the Y-axis of the plate reference frame 244. In one example, the second linear axis of motion 170 is parallel to the first rotational axis of motion 162. In one example, the second linear axis of motion 170 is perpendicular to the first linear axis of motion 168. In one example, the second linear motion axis 170 intersects the first linear motion axis 168.

In an example, selective linear movement of backing plate 106 along second linear axis of motion 170 selectively positions backing plate 106 relative to delivery head 114 such that backing plate 106 is in position for delivery head 114 to contact backing plate 106, and plate surface 146 of backing plate 106 acts as a portion of first web layer 374 (fig. 8) for placing composite tape 104 on placement surface 222 to form web 328 as delivery head 114 passes along a placement path. In an example, selective linear movement of back plate 106 along second linear axis of motion 170 selectively positions back plate 106 relative to first web layer 374 of web 328 such that back plate 106 is in position for delivery head 114 to contact first layer 228 (fig. 8) of composite tape 104, which first layer 228 serves as placement surface 222 for placing second layer 232 (fig. 8) of composite tape 104 on first layer 228 to form a portion of second web layer 382 (fig. 10) of web 328, and so on.

As described hereinabove, when composite tape 104 is laid out, delivery head 114 moves relative to environmental reference frame 340 and backing plate 106, and backing plate 106 may move relative to delivery head 114 but remain fixed relative to environmental reference frame 340. Thus, when composite tape 104 is disposed on backing plate 106, selective linear movement of backing plate 106 along second linear axis of motion 170 is also consistent with movement of delivery head 114 relative to backing plate 106 along the placement path.

In some examples, the apparatus 100 includes a third linear axis of motion 172. Backing plate 106 is linearly movable relative to delivery head 114 along a third linear axis of motion 172. In an example, the back plate 106 may be linearly movable along the third linear motion axis 172 in the direction of the third linear motion direction arrow 192. In an example, as illustrated in fig. 11 and 12, when back plate 106 is selectively positioned to enable delivery head 114 to dispose composite tape 104 on mandrel 116 (fig. 7), linear movement of back plate 106 along third linear axis of motion 172 moves back plate 106 such that back plate 106 does not interfere with or otherwise interfere with the placement of composite tape 104 on mandrel 116. In an example, as illustrated in fig. 13 and 14, when the back plate 106 is selectively positioned to enable the delivery head 114 to dispose the composite strip 104 on the back plate 106 (fig. 7), linear movement of the back plate 106 along the third linear axis of motion 172 moves the back plate 106 such that the back plate 106 is in position to act as the placement surface 222 for disposing the composite strip 104 and to react the placement force 112.

In one example, the third linear axis of motion 172 passes through the back plate 106. In one example, the third linear motion axis 172 is parallel to the Z-axis of the plate reference frame 244. In one example, the third linear axis of motion 172 is perpendicular to the second linear axis of motion 170. In one example, the third linear axis of motion 172 intersects the second linear axis of motion 170. In one example, the third linear axis of motion 172 is perpendicular to the first linear axis of motion 168. In one example, the third linear axis of motion 172 intersects the first linear axis of motion 168.

In an example, selective linear movement of back plate 106 along third linear axis of motion 172 selectively positions back plate 106 relative to delivery head 114 such that back plate 106 is in position for delivery head 114 to contact back plate 106, and plate surface 146 of back plate 106 acts as a portion of first web layer 374 (fig. 10) that serves as a placement surface for placing composite tape 104 as delivery head 114 passes along a placement path to form web 328. In an example, selective linear movement of back plate 106 along third linear axis of motion 172 selectively positions back plate 106 relative to first web layer 374 of web 328 such that back plate 106 is in position for delivery head 114 to contact first layer 228 (fig. 8) of composite tape 104, which first layer 228 serves as placement surface 222 for placing second layer 232 (fig. 8) of composite tape 104 on first layer 228 to form a portion of second web layer 382 (fig. 10) of web 328, and so on.

As described hereinabove, when composite tape 104 is laid out, delivery head 114 moves relative to environmental reference frame 340 and backing plate 106, and backing plate 106 may move relative to delivery head 114 but remain fixed relative to environmental reference frame 340. Thus, when composite tape 104 is disposed on backing plate 106, selective linear movement of backing plate 106 along third linear axis of motion 172 also coincides with movement of delivery head 114 relative to backing plate 106 along the placement path.

In one example, the apparatus 100 includes a second axis of rotational motion 164. Backing plate 106 is rotationally movable relative to delivery head 114 about a second rotational axis of motion 164. In an example, back plate 106 is rotationally movable about second rotational motion axis 164 in a direction indicated by second rotational motion direction arrow 196. For example, rotational movement of back plate 106 about second rotational motion axis 164 orbits back plate 106 at least partially around delivery head 114. In an example, as illustrated in fig. 13 and 14, when back plate 106 is selectively positioned to enable delivery head 114 to dispose composite tape 104 on back plate 106 (fig. 8), rotational movement of back plate 106 about second rotational axis of motion 164 changes or adjusts the angular orientation of back plate 106 relative to compaction roller 124.

In one example, second rotational axis of motion 164 passes through delivery head 114. In one example, the second rotational axis of motion 164 is parallel to the Z-axis of the head reference frame 242. In one example, the second rotational axis of motion 164 is perpendicular to the first rotational axis of motion 162. In one example, the second rotational axis of motion 164 intersects the first rotational axis of motion 162.

Selective rotational movement of back plate 106 about second rotational axis of motion 164 selectively positions back plate 106 relative to delivery head 114 such that back plate 106 is in position for delivery head 114 to contact back plate 106, and plate surface 146 of back plate 106 serves as a portion of a first web layer 374 (fig. 10) for placing composite tape 104 using tape placement machine 102 to form web 328. In an example, selective linear movement of back plate 106 along second rotational axis of motion 164 selectively positions back plate 106 relative to first web layer 374 of web 328 such that back plate 106 is in position for delivery head 114 to contact first layer 228 (fig. 8) of composite tape 104, which first layer 228 serves as placement surface 222 for folding first layer 228 (fig. 8) of composite tape 104 onto itself to form a supplemental portion of first web layer 374 (fig. 10) of web 328, and so on.

In one example, the apparatus 100 includes a third axis of rotational motion 166. Backing plate 106 is rotationally movable relative to delivery head 114 about third rotational axis of motion 166. In an example, back plate 106 is rotationally movable about third rotational motion axis 166 in a direction indicated by third rotational motion direction arrow 198. For example, rotational movement of back sheet 106 about third rotational axis of motion 166 changes or adjusts the angular orientation of back sheet 106 relative to delivery head 114 and, more specifically, relative to compaction roller 124. In an example, as illustrated in fig. 11 and 12, when back plate 106 is selectively positioned to enable delivery head 114 to dispose composite tape 104 on mandrel 116 (fig. 7), rotational movement of back plate 106 about third rotational axis of motion 166 moves back plate 106 such that back plate 106 does not interfere with or otherwise interfere with the placement of composite tape 104 on mandrel 116. In an example, when the backing plate 106 is selectively positioned to enable the delivery head 114 to dispose the composite tape 104 on the backing plate 106 (fig. 8), rotational movement of the backing plate 106 about the third rotational axis of motion 166 moves the backing plate 106 such that the backing plate 106 is in position to act as the placement surface 222 for disposing the composite tape 104 and react the placement force 112.

In one example, the third axis of rotational movement 166 passes through the back plate 106. In one example, the third rotational axis 166 is parallel to the Y-axis of the plate reference frame 244. In one example, the third axis of rotational movement 166 is parallel to the second axis of linear movement 170. In an example, the third rotational axis of motion 166 is coincident with (e.g., coaxial with) the second linear axis of motion 170. In one example, the third rotational axis of motion 166 is parallel to the second rotational axis of motion 164.

In an example, selective rotational movement of back plate 106 about third rotational axis of motion 166 selectively orients back plate 106 relative to delivery head 114, and more specifically relative to compaction roller 124, such that back plate 106 is in position for delivery head 114 to contact back plate 106, and plate surface 146 of back plate 106 serves as a placement surface for placing composite tape 104 to form a portion of first web layer 374 (fig. 10) of web 328. In an example, selective rotational movement of back plate 106 about third rotational axis of motion 166 selectively positions back plate 106 relative to first web layer 374 of web 328 such that back plate 106 is in position for delivery head 114 to contact first layer 228 (fig. 8) of composite tape 104, which first layer 228 serves as placement surface 222 for placing second layer 232 (fig. 8) of composite tape 104 on first layer 228 to form a portion of second web layer 382 (fig. 10) of web 328, and so on.

As described hereinabove, when composite tape 104 is laid out, delivery head 114 moves relative to environmental reference frame 340 and backing plate 106, and backing plate 106 may move relative to delivery head 114 but remain fixed relative to environmental reference frame 340. Thus, when composite tape 104 is disposed on backing plate 106, selective rotational movement of backing plate 106 about third rotational axis of motion 166 also coincides with movement of delivery head 114 relative to backing plate 106 along the placement path.

Still referring to fig. 11-14, in one example, the reaction structure 226 includes a drive assembly 174. Drive assembly 174 movably couples backing plate 106 and delivery head 114. Drive assembly 174 is configured to move back plate 106 linearly relative to delivery head 114, e.g., along one or more of first linear axis of motion 168, second linear axis of motion 170, and third linear axis of motion 172. Drive assembly 174 is also configured to rotationally move back plate 106 relative to delivery head 114, e.g., about one or more of first rotational axis of motion 162, second rotational axis of motion 164, and third rotational axis of motion 166.

In an example, the reaction structure 226 includes a support mount 176. The support mount 176 is coupled to the tape placement machine 102, e.g., to the delivery head 114. Reaction structure 226 also includes an arm 178. In an example, the arm 178 is rotationally coupled with the support mount 176 via the drive assembly 174. Back plate 106 is coupled to arm 178 opposite support mount 176. In one example, the arm 178 is adjustable in length via the drive assembly 174. In other words, arm 178 has a selectively adjustable length to move back plate 106 linearly relative to delivery head 114, e.g., along first linear axis of motion 168. Rotation of arm 178 relative to support mount 176 orbitally rotates back plate 106 at least partially around delivery head 114.

In some examples, the reaction structure 226 includes an opposing pair of arms 178. A first end of a first one of the pair of arms 178 is rotationally coupled to support mount 176 at a first location via drive assembly 174. A first end of a second of the pair of arms 178 is rotationally coupled to support mount 176 via drive assembly 174 at a second location axially opposite the first location. A second end of a first one of the pair of arms 178 is coupled to the back plate 106 at a first location. A second end of a second of the pair of arms 178 is coupled to the back plate 106 at a second location axially opposite the first location. The pair of arms 178 rotate together to rotationally move the back plate 106.

In some examples, the reaction structure 226 includes only one arm 178. A first end of arm 178 is rotationally coupled to support mount 176 via drive assembly 174. The second end of arm 178 is coupled to back plate 106. The pair of arms 178 may advantageously reduce undesirable torque that may be applied to back plate 106 due to placement forces 112 (fig. 5 and 6) applied by delivery head 114 as compared to one arm 178.

In an example, the arm 178 or each of the pair of arms 178 includes a plurality of arm segments 200 coupled together. At least one of arm segments 200 is linearly movable relative to another of arm segments 200 via drive assembly 174 to selectively adjust the overall length of arm 178, and thus linearly move back plate 106 relative to delivery head 114 along first linear motion axis 168. In one example, the arm 178 is a telescoping arm. For example, a first one of the arm segments 200 comprises a hollow tubular member and a second one of the arm segments 200 telescopes within the first one of the arm segments 200 to adjust the overall length of the arm 178 and linearly move the back plate 106.

In one example, the drive assembly 174 includes an arm linear actuator 202 associated with the arm 178 or each of the pair of arms 178. In an example, the arm linear actuator 202 is operably coupled with adjacent ones of the arm segments 200 of the arm 178 or each of the pair of arms 178. Arm linear actuator 202 is configured to selectively adjust the length of arm 178, and thus, selectively move back plate 106 linearly along first linear axis of motion 168 relative to delivery head 114. In an example, the arm linear actuator 202 is configured to selectively determine a position of at least one of the arm segments 200 relative to adjacent ones of the arm segments 200 and to fix or secure the arm segments 200 relative to one another.

In some examples, the arm linear actuator 202 includes a hydraulic linear actuator, a pneumatic linear actuator, a mechanical or electromechanical linear actuator, or other suitable type of linear actuation mechanism. In some examples, the arm linear actuator 202 includes a stepper motor, a servo motor, or the like.

In other examples, drive assembly 174 may include additional linear actuators or other types of length adjustment mechanisms configured to selectively adjust the length of arm 178 or each of the pair of arms 178, and to selectively fix the relative position of arm 178 or each of the pair of arms 178 to selectively move back plate 106 linearly relative to delivery head 114.

In one example, the drive assembly 174 includes an arm rotation actuator 204 associated with the arm 178 or each of the pair of arms 178. An arm rotation actuator 204 is operably coupled with the arm 178 or each of the pair of arms 178. Arm rotation actuator 204 is configured to selectively rotationally move back plate 106 relative to delivery head 114 about first rotational axis of motion 162.

In an example, as illustrated in fig. 11, an arm rotation actuator 204 is coupled to the support mount 176 and is operably coupled with the arm 178 or each of the pair of arms 178. An arm rotation actuator 204 movably couples the arm 178 or each of the pair of arms 178 and the support mount 176 together. Arm rotation actuator 204 is configured to selectively rotate arm 178 about first rotational axis of motion 162 relative to support mount 176 and, thus, selectively rotationally move back plate 106 relative to delivery head 114. In this example, the first rotational axis of motion 162 passes through the arm 178 or each of the pair of arms 178 and the support mount 176, for example, at the location where the arm 178 is coupled to the support mount 176.

In an example, as illustrated in fig. 12, the arm rotation actuator 204 is operably coupled with adjacent ones of the arm segments 200 of the arm 178 or each of the pair of arms 178. Arm rotation actuator 204 is configured to selectively rotate one of arm segments 200 about first rotational axis of motion 162 relative to an adjacent one of arm segments 200, and thus, selectively rotationally move back plate 106 relative to delivery head 114. In this example, the first rotational axis of motion 162 passes through the arm 178 or each of the pair of arms 178 at a location along the arm 178 between the support mount 176 and the back plate 106.

In an example, as illustrated in fig. 12, the arm 178 or each of the pair of arms 178 includes a pivot joint movably coupling a first one of the arm segments 200 and a second one of the arm segments 200, and the pivot joint defines the first rotational movement axis 162. An arm rotation actuator 204 is operably coupled with a first one of the arm segments 200 and a second one of the arm segments 200 at a pivot joint. Arm rotation actuator 204 is configured to selectively rotationally move back plate 106 about first rotational axis of motion 162 relative to a second one of the first rotational arm segments 200 of arm segments 200, and thus, selectively relative to delivery head 114.

In some examples, arm rotation actuator 204 includes a hydraulic rotation actuator, a pneumatic rotation actuator, a mechanical or electromechanical rotation actuator, or other suitable type of rotational actuation mechanism. In some examples, the arm rotation actuator 204 includes a stepper motor, a servo motor, a rotary vane actuator, an electric rotation actuator, or the like.

In other examples, drive assembly 174 may include additional rotary actuators or other types of rotary adjustment mechanisms configured to selectively adjust the angular orientation of arm 178 or each of the pair of arms 178, and configured to selectively fix the angular orientation of arm 178 or each of the pair of arms 178 to selectively rotationally move back plate 106 relative to delivery head 114.

In one example, the drive assembly 174 includes a first linear track 180. A first linear track 180 is coupled to arm 178 opposite support mount 176. The back plate 106 is operably coupled with the first linear rail 180. Linear movement of back plate 106 relative to first linear rail 180 linearly moves back plate 106 relative to delivery head 114 along second linear axis of motion 170.

In an example, a first end of the first linear track 180 is coupled to a second end of a first one of the pair of arms 178 opposite the support mount 176, and a second end of the first linear track 180 is coupled to a second end of a second one of the pair of arms 178 opposite the support mount 176.

In one example, the drive assembly 174 includes a plate linear actuator 206 (fig. 11 and 12). Plate linear actuator 206 operably (e.g., movably) couples back plate 106 with first linear track 180. Plate linear actuator 206 is configured to traverse first linear track 180 to selectively linearly move back plate 106 relative to first linear track 180 and thus relative to delivery head 114 along second linear axis of motion 170. In one example, the second linear axis of motion 170 passes through the first linear track 180.

In an example, first linear track 180 includes any suitable structure that defines a route or line of travel or movement of back plate 106 along second linear axis of motion 170. In an example, plate linear actuator 206 comprises any suitable device configured to traverse first linear rail 180. In one example, the first linear track 180 includes a linear gear or rack. The plate linear actuator 206 includes a circular gear or pinion that engages a linear gear. The plate linear actuator 206 also includes a motor, such as a stepper motor or a servo motor, that is operably coupled to the circular gear and configured to rotate the circular gear to cause the circular gear to move linearly relative to or along the linear gear. Selective linear movement of plate rotation actuator 208 relative to (e.g., along) first linear track 180 selectively moves backing plate 106 linearly relative to delivery head 114.

In other examples, first linear track 180 and plate linear actuator 206 may include other structures and mechanisms suitable for selectively controlling linear movement of back plate 106 relative to delivery head 114. In an example, the first linear track 180 includes one or more guide rails and the plate linear actuator 206 includes a motorized support configured to travel along the guide rails.

In one example, the drive assembly 174 includes a second linear track 182. The second linear rail 182 is operably (e.g., movably) coupled with the first linear rail 180. The second linear rail 182 is linearly movable relative to the first linear rail 180. The back plate 106 is coupled to the second linear rail 182. Linear movement of second linear track 182 relative to first linear track 180 moves back plate 106 linearly along third linear axis of motion 172 relative to first linear track 180 and thus relative to delivery head 114. In one example, the third linear motion axis 172 passes through the second linear track 182. In an example, as illustrated in fig. 11 and 12, the second linear track 182 is perpendicular to the first linear track 180.

In an example, the plate linear actuator 206 operably (e.g., movably) couples the second linear track 182 with the first linear track 180. Plate linear actuator 206 is configured to traverse second linear track 182 to selectively move second linear track 182 linearly relative to first linear track 180, and thus, selectively move back plate 106 linearly along third linear axis of motion 172 relative to delivery head 114.

In an example, the second linear track 182 includes any suitable structure that defines a path or line of travel or movement of the back plate 106 along the third linear axis of motion 172. In an example, the second linear rail 182 is coupled to a rear surface 210 of the back plate 106 opposite the plate surface 146. In an example, the plate linear actuator 206 is any suitable device configured to traverse the second linear track 182. In one example, the second linear track 182 includes a linear gear or rack. The plate linear actuator 206 includes a second circular gear or pinion that engages the linear gear. The plate linear actuator 206 also includes a second motor, such as a stepper motor or a servo motor, that is operably coupled to the second circular gear and that is configured to rotate the second circular gear to cause the second circular gear to move linearly relative to or along the linear gear. Selective linear movement of plate rotation actuator 208 relative to (e.g., along) second linear track 182 selectively moves back plate 106 linearly relative to delivery head 114.

In other examples, second linear track 182 and plate linear actuator 206 may include other structures and mechanisms suitable for selectively controlling linear movement of back plate 106 relative to delivery head 114. In an example, the second linear track 182 includes one or more guide rails and the plate linear actuator 206 includes a motorized support configured to travel along the guide rails.

In the illustrative example, drive assembly 174 includes one plate linear actuator 206, the plate linear actuator 206 is operably coupled with both the first linear track 180 and the second linear track 182, and the plate linear actuator 206 is configured to pass through both the first linear track 180 and the second linear track 182 to selectively move the backing plate 106 linearly relative to the delivery head 114 along the second linear axis of motion 170 and the third linear axis of motion 172. In other examples, the drive assembly 174 may include additional (e.g., multiple) plate linear actuators 206. For example, a first one of plate linear actuators 206 is operably coupled with first linear track 180 and is configured to traverse first linear track 180 to selectively move back plate 106 linearly along second linear axis of motion 170 relative to delivery head 114. A second one of the plate linear actuators 206 is operably coupled with the second linear track 182 and is configured to traverse the second linear track 182 to selectively move the back plate 106 linearly along the third linear axis of motion 172 relative to the delivery head 114.

In one example, the support mount 176 includes an angled track 184. Angular track 184 is coupled to delivery head 114. The drive assembly 174 includes a carriage 186. The carriage 186 is operatively coupled with the angle track 184 and is movable along the angle track 184. The arm 178 is rotationally coupled with the carriage 186. Movement of carriage 186 along angular track 184 orbitally rotates back plate 106 about delivery head 114. In other words, movement of carriage 186 along angular track 184 rotationally moves back plate 106 relative to delivery head 114 about second rotational axis of motion 164.

In an example, angular track 184 is coupled to delivery head 114 such that second rotational axis of motion 164 passes through a radial center of angular track 184. Angular track 184 is coupled to delivery head 114 in such a manner: so as not to interfere with the manipulation, delivery, or placement of the composite tape 104 on the placement surface 222.

In an example, angular track 184 includes any suitable structure that defines a route or line of travel or movement of back plate 106 about second rotational movement axis 164. In an example, the carriage 186 includes any suitable device configured to traverse the angular track 184. In an example, the angular track 184 includes an annular rack and the carriage 186 includes a motorized gearbox powered by, for example, a stepper motor or a servo motor, configured to engage and move relative to (e.g., along) the annular rack. In an example, the angular track 184 includes one or more guide rails and the carriage 186 includes a motorized support configured to move along the guide rails.

In some examples, the drive assembly 174 includes an opposing pair of carriages 186. A first one of the pair of carriages 186 is operatively coupled to the angular track 184. A second one of the pair of carriages 186 is operatively coupled to the angular track 184 at a position axially loudness with the first one of the pair of carriages 186. The pair of carriages 186 are configured to at least partially traverse the angular track 184 together while maintaining their axially opposite positions.

In an example, the arm 178 is rotationally coupled with the carriage 186. Movement of carriage 186 along angular track 184 selectively rotationally moves arm 178 about second rotational axis of motion 164, and thus, selectively rotationally moves back plate 106 relative to delivery head 114 about second rotational axis of motion 164. In an example, the arm rotation actuator 204 is coupled to the carriage 186, and the arm 178 is operably coupled with the arm rotation actuator 204. Arm rotation actuator 204 is configured to rotationally move arm 178, and thus, selectively rotationally move back plate 106, relative to delivery head 114 about first rotational motion axis 162, relative to carriage 186 about first rotational motion axis 162.

In one example, the drive assembly 174 includes a plate rotation actuator 208. In an example, plate rotation actuator 208 is coupled to arm 178 and operably coupled with back plate 106. Plate rotation actuator 208 is configured to selectively rotate back plate 106 relative to arm 178 about third rotational axis of motion 166, and thus, selectively rotationally move back plate 106 relative to the delivery head, and more specifically relative to compaction roller 124. In the illustrative example, the third rotational axis of motion 166 passes through the arm 178 or each of the pair of arms 178 and the back plate 106 at the location where the arm 178 is coupled to the back plate 106.

In some examples, the plate rotation actuator 208 includes a hydraulic rotation actuator, a pneumatic rotation actuator, a mechanical or electromechanical rotation actuator, or other suitable type of rotation actuation mechanism. In some examples, the plate rotation actuator 208 includes a stepper motor, a servo motor, a rotary vane actuator, an electrical rotation actuator, and the like.

Referring to fig. 13 and 14, depending on the angular orientation of backing plate 106 relative to delivery head 114, and more specifically relative to compaction roller 124, defined by rotational movement of backing plate 106 about second rotational movement axis 164 and the direction of the placement path of composite tape 104 (fig. 8), any of first plate end 212, second plate end 214, third plate end 216, and fourth plate end 218 may define either of first plate position 156 or second plate position 158 (fig. 8) as delivery head 114 is moved along plate surface 146 to place composite tape 104.

Referring to fig. 15, in one example, the drive assembly 174 includes a plurality of first linear rails 180 and a plurality of second linear rails 182. In an example, a first one of the second linear rails 182 is coupled to the rear surface 210 of the back plate 106 adjacent the first plate end 212 (e.g., upper plate end) and the fourth plate end 218 (e.g., right plate end). A second one of the second linear rails 182 is coupled to the rear surface 210 of the back plate 106 adjacent a second plate end 214 (e.g., a lower plate end) and a third plate end 216 (e.g., a left plate end). Each of the first one of the first linear tracks 180 and the second one of the first linear tracks 180 is operably coupled with the first one of the second linear tracks 182 and the second one of the second linear tracks 182, for example, by a corresponding one of the plurality of plate linear actuators 206. A first one of the first linear tracks 180 and a second one of the first linear tracks 180 are spaced apart from each other. The utilization and relative position of first linear rail 180 and second linear rail 182 provides increased structural support to drive assembly 174 and back plate 106 and increases the ability or performance of back plate 106 to react to the placement force exerted by delivery head 114 when placing composite tape 104.

In one example, the reaction structure 226 includes a pair of linkages 220 coupling the arm 178 and the first linear rail 180 together. In an example, a first one of the linkages 220 is coupled (e.g., pivotally coupled) with the arm 178 and is coupled (e.g., pivotally coupled) with a first one of the first linear rails 180. A second one of the linkages 220 is coupled (e.g., pivotally coupled) to the arm 178 and is coupled (e.g., pivotally coupled) to a second one of the first linear rails 180.

In some examples, each of the first and second

linear rails

180, 182 may have any of a variety of different lengths, configurations, and/or positions and orientations relative to the backplane 106. Generally, the or each first linear track 180 has a length suitable to enable linear movement of back plate 106 along first linear track 180, the linear movement of back plate 106 along first linear track 180 being sufficient to selectively position back plate 106 along second linear motion axis 170 relative to delivery head 114 when composite tape 104 is being disposed on back plate 106 by tape placement machine 102 (as illustrated in fig. 8). Similarly, the second linear track 182, or each of the second linear tracks 182, has a length suitable to effect linear movement of the back plate 106 along the second linear track 182, the linear movement of the back plate 106 along the second linear track 182 being sufficient to selectively position the back plate 106 along the third linear motion axis 172 relative to the delivery head 114 when the composite tape 104 is being disposed on the back plate 106 by the tape placement machine 102.

Referring to fig. 16, an example of a method 1000 for forming a composite structure 300 using the disclosed apparatus 100 is also disclosed. Generally, as illustrated in fig. 17-30, method 1000 utilizes selective positioning of backing plate 106 relative to delivery head 114 of tape placement machine 102 such that plate surface 146 serves as placement surface 222 for arranging composite tape 104 to form a portion of composite structure 300. In an example, the method 1000 is used to form a composite structure 300, the composite structure 300 including a composite panel 302, such as a composite skin panel, having a number of composite stiffeners 308 (such as composite stringers). In various examples, method 1000 utilizes disclosed apparatus 100 to form composite stiffeners 308 in situ on composite panel 302. The method 1000 includes selectively positioning the backing plate 106 to serve as a placement surface 222 for placing the composite tape 104 and reacting the placement force 112 applied by the delivery head 114 when increasing the layers of the composite stiffener 308.

In an example, the method 1000 includes the step of forming the composite panel 302. In an example, the composite panel 302 is formed by laying up a plurality of plies 336 (fig. 2-4) of composite material, for example, on a mandrel 116 (fig. 7). In some examples, the plies 336 of composite material are sheets of composite material. In some examples, the plies 336 of composite material are layers of composite tape 104 that are placed, for example, by the tape placement machine 102, prior to forming the composite reinforcement 308. In some examples, at least one of the plies 336 of composite material forming the composite panel 302 and at least one of the plies 334 of the composite tape 104 forming the composite reinforcement 308 are the same. In other words, in some examples, composite panel 302 and composite stiffener 308 share at least some layers of composite material.

In one example, the method 1000 includes the step of placing a radius filler 338 on the composite panel 302 prior to laying up the composite tape 104 to form the composite stiffener 308. In some examples, the radius filler 338 has sufficient adhesion or thickness such that the radius filler 338 is coupled to the inner surface 330 of the composite panel 302. In some examples, the radius filler 338 is adhesively bonded to the inner surface 330 of the composite panel 302.

Referring to fig. 16, in an example, the method 1000 includes the step of laying up the continuous segments 342 of the composite tape 104 on the composite panel 302 using the delivery head 114 of the tape placement machine 102 to form the flange portions 304 of the initial plies 306 of the composite reinforcement 308 (block 1002). In an example, the initial ply 306 or first ply is one of the plies 334 (fig. 2-4) of the composite tape 104 that are laid up to form the composite reinforcement 308. In an example, the flange portion 304 of the initial ply 306 (fig. 17) forms a portion (e.g., a layer) of the flange 332 (fig. 2-4) of the composite stiffener 308. For example, flange portion 304 of initial laminate 306 is part of first flange 372 of flange 332 (FIG. 10).

Referring to fig. 17, in an example, delivery head 114 is selectively positioned and oriented relative to composite panel 302, e.g., by movement system 130 (fig. 5). In an example, the position and orientation of the composite panel 302, e.g., formed on the mandrel 116, relative to the environmental reference frame 340 is fixed. The delivery head 114 is then selectively moved relative to the composite panel 302 to arrange the continuous segments 342 of the composite strip 104 on the composite panel 302 to form the flange portion 304 of the initial plies 306 of the composite stiffener 308. For example, delivery head 114 is moved linearly relative to environmental reference frame 340 (e.g., along or parallel to the Z-axis of environmental reference frame 340) along a placement path indicated by directional arrow 110 such that successive segments 342 of composite tape 104 are placed by delivery head 114 on inner surface 330 of composite panel 302 serving as placement surface 222. As the composite strip 104 is arranged, the compaction roller 124 immediately or subsequently compresses the continuous segment 342 of the composite strip 104.

In an example, the method 1000 includes the step of laying up the continuous segments 342 of the composite tape 104 over the radius filler 338 with the delivery head 114 to form the transition portions of the initial plies 306 of the composite reinforcement 308. In an example, the transition portion of the initial plies 306 forms a portion (e.g., a layer) of the transition 364 (fig. 2-4) of the composite reinforcement 308.

Still referring to fig. 17, in an example, delivery head 114 is then selectively moved relative to composite panel 302 and radius filler 338 to transition from composite panel 302 to radius filler 338 and to dispose continuous section 342 of composite strip 104 on radius filler 338. For example, delivery head 114 is moved linearly relative to environmental reference frame 340 (e.g., along an X-axis of environmental reference frame 340) and/or rotationally relative to environmental reference frame 340 (e.g., about a Y-axis of environmental reference frame 340) such that continuous section 342 of composite strip 104 is placed by delivery head 114 on radius filler 338, which serves as placement surface 222. As the composite strip 104 is arranged, the compaction roller 124 immediately or subsequently compresses the continuous segment 342 of the composite strip 104.

As the delivery head 114 transitions from disposing the composite tape 104 on the composite panel 302 to disposing the composite tape 104 on the radius filler 338, a sufficient length of the composite tape 104 is fed from the delivery head 114 so as not to lift or otherwise pull the continuous segment 342 of the composite tape 104 of the flange portion 304 of the formed initial ply 306 from the inner surface 330 of the composite panel 302.

In some examples, as illustrated in fig. 17, the radius filler 338 is sufficiently coupled (e.g., adhered) to the inner surface 330 of the composite panel 302 such that when the composite tape 104 is disposed on the radius filler 338 and transitions from the flange portion 304 of the initial ply 306 to the web portion 310 (fig. 17) of the initial ply 306 of the composite reinforcement 308, the radius filler 338 remains in place and reacts to the placement force 112 applied by the delivery head 114.

In some examples, as illustrated in fig. 18, when composite tape 104 is arranged by delivery head 114, backing sheet 106 is selectively positioned relative to composite face sheet 302, radius filler 338, and delivery head 114 to support radius filler 338. For example, back plate 106 is moved linearly relative to environmental reference frame 340 (e.g., along a Z-axis of environmental reference frame 340) and/or rotationally relative to environmental reference frame 340 (e.g., about a Y-axis of environmental reference frame 340) such that a portion of back plate 106 is in contact with a side of radius filler 338 opposite delivery head 114. In this example, when the composite tape 104 is disposed over the radius filler 338 and transitions from the flange portion 304 of the initial ply 306 to the web portion 310 of the initial ply 306 of the composite reinforcement 308 (FIG. 19), the back plate 106 holds the radius filler 338 in place and reacts to the placement force 112 applied by the delivery head 114. In an example, a portion of back plate 106 has a shape that corresponds to the shape of the portion of radius filler 338 on which back plate 106 makes contact.

Referring to fig. 16, in an example, method 1000 includes the step of positioning back plate 106 coupled to delivery head 114 relative to composite face plate 302 (block 1004). The step of positioning the backing sheet 106 relative to the composite face sheet 302 follows the steps of laying up the continuous segments 342 of the composite tape 104 on the composite face sheet 302 to form the flange portion 304 of the initial ply 306 of the composite reinforcement 308 and laying up the continuous segments 342 of the composite tape 104 on the radius filler 338 to form the transition portion of the initial ply 306 of the composite reinforcement 308.

Referring to fig. 19, in an example, backplane 106 is selectively moved (e.g., determines a position and orientation) relative to composite panel 302, such as by drive assembly 174 (fig. 5). For example, backplate 106 is moved linearly relative to environmental reference frame 340 (e.g., along the X-axis and/or Z-axis of environmental reference frame 340) and/or rotationally relative to environmental reference frame 340 (e.g., about the Y-axis of environmental reference frame 340) such that plate surface 146 is properly positioned to serve as placement surface 222.

In an example, back-plate 106 is positioned approximately perpendicular to inner surface 330 of composite face plate 302. In other examples, back-plate 106 is positioned at any of a variety of other (e.g., oblique) angles relative to inner surface 330 of composite face plate 302.

Referring to fig. 16, in an example, method 1000 includes the step of laying up continuous segments 342 of composite tape 104 on backing plate 106 with delivery head 114 to form web portions 310 of initial plies 306 of composite stiffeners 308 (block 1006). In an example, the web portion 310 of the initial plies 306 (FIG. 19) forms a portion (e.g., a layer) of the web 328 (FIGS. 2-4) of the composite stiffener 308. For example, the web portion 310 of the initial ply 306 is part of a first web layer 374 of the web 328 (FIG. 9).

Referring to fig. 19, in an example, the delivery head 114 is selectively moved (e.g., positions and/or orientations determined) relative to the composite face sheet 302 and the back sheet 106 to arrange the continuous segments 342 of the composite tape 104 on the back sheet 106 to form the web portions 310 of the initial plies 306 of the composite stiffeners 308. For example, delivery head 114 is moved linearly relative to environmental reference frame 340 (e.g., along or parallel to the Z-axis of environmental reference frame 340) along a placement path indicated by directional arrow 234 such that a continuous segment 342 of composite tape 104 is placed by delivery head 114 on panel surface 146 of composite panel 302 serving as placement surface 222. As the composite strip 104 is arranged, the compaction roller 124 immediately or subsequently compresses the continuous segment 342 of the composite strip 104.

As delivery head 114 is moved relative to composite face sheet 302 and back sheet 106 to dispose continuous segments 342 of composite tape 104 on back sheet 106 to form web portions 310 of initial plies 306 of composite reinforcement 308, a sufficient length of composite tape 104 is fed from delivery head 114 so as not to lift or otherwise pull continuous segments 342 of composite tape 104 forming flange portions 304 of initial plies 306 from inner surface 330 of composite face sheet 302 or radius fillers 338.

In general, the orientation of web portions 310 of initial plies 306 of composite stiffener 308 relative to flange portions 304 of initial plies 306 of composite stiffener 308 depends on the orientation of back plate 106 relative to composite panel 302 and/or environmental reference 340. In an example, the web portion 310 of the initial ply 306 is disposed approximately perpendicular to the flange portion 304 of the initial ply 306. In other examples, the web portion 310 of the initial ply 306 is arranged at any of various other (e.g., oblique) angles relative to the flange portion 304 of the initial ply 306.

Generally, back plate 106 is selectively positioned relative to delivery head 114 and composite face plate 302 prior to laying up continuous segments 342 of composite tape 104 on back plate 106 to form web portions 310 of initial plies 306 of composite stiffeners 308. Plate surface 146 of backing plate 106 acts as a placement surface 222 for placing composite tape 104, and backing plate 106 reacts to placement force 112 (fig. 5 and 6) applied by delivery head 114 when placing composite tape 104 through reaction structure 226 and back to delivery head 114. In some examples, backplane 106 is selectively positioned with respect to delivery head 114 or environmental reference frame 340 by at least one of moving backplane 106 rotationally about first rotational axis of motion 162 (fig. 11-14), moving backplane 106 linearly along first linear axis of motion 168 (fig. 11-14), moving backplane 106 linearly along second linear axis of motion 170 (fig. 11-14) with respect to delivery head 114, moving backplane 106 linearly along third linear axis of motion 172 (fig. 11-14) with respect to delivery head 114, and moving backplane 106 rotationally about third rotational axis of motion 166 (fig. 11-14) with respect to delivery head 114.

In an example, back plate 106 is selectively rotationally moved about at least one of first rotational axis of motion 162 and second rotational axis of motion 166 to orient back plate 106 relative to composite panel 302 at an angular orientation corresponding to an angular orientation of web portion 310 of initial plies 306 (e.g., web 328 of composite stiffener 308) relative to inner surface 330 of composite panel 302. In an example, backing plate 106 is selectively moved linearly along first linear axis of motion 168 toward delivery head 114 to position backing plate 106 for placement of composite tape 104. In an example, the back plate 106 is selectively moved linearly along the third linear axis of motion 172 such that the arms 178 of the drive assembly 174 do not interfere with the portion of the composite stiffener 308 being laid or having been previously laid.

Referring to fig. 16, in an example, method 1000 includes the steps of fixing the position of back sheet 106 relative to composite face sheet 302 (block 1008) and moving delivery head 114 relative to back sheet 106 while laying composite tape 104 on back sheet 106 to form web portions 310 of initial plies 306 of composite stiffener 308 (block 1010).

Referring to fig. 19, in an example, the position of back sheet 106 relative to composite face sheet 302, radius filler 338 is fixed as back sheet 106 is selectively positioned for placement of composite tape 104. Delivery head 114 moves relative to composite face sheet 302, radius filler 338, and back sheet 106 to place composite tape 104 on back sheet 106 and form a portion of composite stiffener 308. In an example, back plate 106 is fixed relative to environmental reference frame 340, and delivery head 114 is moved linearly relative to environmental reference frame 340 along a placement path indicated by directional arrow 234 (e.g., along or parallel to a Z-axis of environmental reference frame 340) to place continuous segments 342 of composite tape 104 on back plate 106 to form web portion 310 of initial plies 306 of composite stiffener 308. Thus, during placement of composite tape 104 on backing plate 106 to form web portion 310 of initial ply 306, delivery head 114 is moved relative to backing plate 106, which backing plate 106 remains stationary and in a fixed position relative to environmental reference 340. Drive assembly 174, which reacts to movement of delivery head 114, maintains a fixed position of backing plate 106 and effects movement of delivery head 114 relative to backing plate 106.

Referring to FIG. 16, in an example, method 1000 includes the step of fixing a position of delivery head 114 relative to composite panel 302 to support an orientation of web portion 310 of initial plies 306 of composite stiffener 308 (block 1012).

Referring to fig. 20, in an example, following the step of laying up the continuous segments 342 of the composite tape 104 on the backing plate 106 to form the web portion 310 of the initial ply 306, the delivery head 114 is selectively moved (e.g., rotationally) relative to the environmental reference frame 340 (e.g., about the Y-axis of the environmental reference frame 340) or the composite panel 302 to support the web portion 310 of the initial ply 306 in preparation for forming the supplemental portion of the web 328. In an example, delivery head 114 supports and maintains web portion 310 of initial plies 306 approximately perpendicular to flange portion 304 of initial plies 306 of composite stiffeners 308.

Referring to FIG. 16, in an example, method 1000 includes the step of moving back plate 106 relative to delivery head 114 to separate back plate 106 from first surface 316 of web portion 310 of initial ply 306 (block 1014).

While the position of delivery head 114 is fixed relative to environmental reference 340 and web portion 310 of initial ply 306 is held in a supported position by delivery head 114, the step of moving back plate 106 to separate back plate 106 from first surface 316 of web portion 310 is performed, as illustrated in fig. 20. In an example, the backplate 106 is selectively moved (e.g., linearly and/or rotationally) relative to the environmental reference frame 340 (e.g., along an X-axis of the environmental reference frame 340 and/or about a Y-axis of the environmental reference frame 340). In an example, back plate 106 is moved relative to delivery head 114 and relative to web portion 310 of initial ply 306 by moving back plate 106 linearly along first linear axis of motion 168 (fig. 11-14) relative to delivery head 114 and/or at least one of back plate 106 rotationally about first rotational axis 162 (fig. 11-14) relative to delivery head 114.

In an example, the method 1000 includes the step of positioning the back plate 106 behind the web portion 310 of the initial plies 306 (block 1016). In other words, the back plate 106 is selectively moved relative to the environmental reference frame 340 or relative to the delivery head 114 and the web portion 310 of the initial ply 306 such that the plate surface 146 of the back plate 106 moves from a first surface 316 facing the web portion 310 to a second surface 350 facing the web portion 310 opposite the first surface 316.

The step of positioning back plate 106 behind web portion 310 of initial ply 306 is performed while the position of delivery head 114 is fixed relative to environmental reference 340 and web portion 310 of initial ply 306 is held in a supported position by delivery head 114, as illustrated in FIG. 20. In an example, the backplate 106 is selectively moved (e.g., rotationally) relative to an environmental reference frame 340 (e.g., about a Z-axis of the environmental reference frame 340). In an example, back plate 106 is moved relative to delivery head 114 and relative to web portion 310 of initial ply 306 by rotationally moving back plate 106 relative to delivery head 114 about second rotational axis of motion 164 (fig. 11-14).

For purposes of this disclosure, the term "behind … …" (such as with reference to backing sheet 106 being positioned behind an article (such as a portion of composite tape 104) or some of the plies 334 forming composite reinforcement 308) refers to backing sheet 106 being positioned in a location where an article is located between backing sheet 106 and delivery head 114 and more particularly between backing sheet 106 and compaction roller 124. For example, because the back sheet 106 is positioned behind the previously laid initial ply 306 of the composite reinforcement 308, the back sheet 106 supports the initial ply 306 acting as the lay-up surface 222 for laying up a subsequent ply of the composite tape 104 and reacts to the lay-up force 112 applied to the initial ply 306 by the delivery head 114 when laying up the subsequent ply of the composite tape 104 on the initial ply 306.

Referring to FIG. 16, in an example, the method 1000 includes the step of moving the back plate 106 relative to the delivery head 114 into engaging contact with a second surface 350 of a web portion 310 of the initial ply 306 opposite the first surface 316 of the web portion 310 of the initial ply 306 (block 1018).

While the position of delivery head 114 is fixed relative to environmental reference 340 and web portion 310 of initial ply 306 is held in a supported position by delivery head 114, the step of moving back plate 106 relative to delivery head 114 into engaging contact with second surface 350 of web portion 310 of initial ply 306 is performed, as illustrated in FIG. 21. In an example, backplate 106 is selectively moved (e.g., linearly and/or rotationally) relative to an environmental reference frame 340 (e.g., along or parallel to an X-axis of environmental reference frame 340 and/or about a Y-axis of environmental reference frame 340). In an example, back plate 106 is selectively moved relative to delivery head 114 and web portion 310 of initial lamina 306 by at least one of rotationally moving back plate 106 about first rotational axis of motion 162 (fig. 11-14), linearly moving back plate 106 along first linear axis of motion 168 (fig. 11-14), linearly moving back plate 106 along second linear axis of motion 170 (fig. 11-14) relative to delivery head 114, linearly moving back plate 106 along third linear axis of motion 172 (fig. 11-14) relative to delivery head 114, and/or rotationally moving back plate 106 about third rotational axis of motion 166 (fig. 11-14) relative to delivery head 114.

In an example, the method 1000 includes the step of folding the continuous segment 342 of the composite tape 104 over itself to begin forming a supplemental portion of the initial ply 306 of the web 328 and transitioning from the web portion 310 of the initial ply 306 to the supplemental web portion 312 of the initial ply 306. In an example, the back plate 106 is selectively positioned in contact with the second surface 350 of the initial ply 306 of the web portion 310. The folded support 352 is positioned in contact with or otherwise engaged with the first surface 316 of the initial laminate 306 of the web portion 310 opposite the back plate 106. The backplate 106 is held in a fixed position relative to an environmental reference frame 340. Delivery head 114 is selectively moved, e.g., linearly and/or rotationally, relative to environmental reference frame 340 (e.g., along or parallel to the X-axis and/or Z-axis of environmental reference frame 340 and/or the Y-axis about environmental reference frame 340) to form folded portion 354 of initial ply 306. In other words, when the delivery head 114 arranges the continuous segments 342 of the composite tape 104 on the folding support 352, the folding support 352 acts as the placement surface 222 to form the folded portion 354 of the initial ply 306. In an example, the folded portion 354 of the initial ply 306 forms a portion (e.g., a layer) of the distal end 362 (fig. 2-4) of the web 328 of the composite stiffener 308.

When the delivery head 114 transitions to dispose the composite tape 104 on the folding support 352, a sufficient length of the composite tape 104 is fed from the delivery head 114 so as not to lift or otherwise pull from the inner surface 330 of the composite panel 302 the continuous segments 342 of the composite tape 104 that form the flange portion 304 of the initial ply 306 and/or not lift or otherwise pull from the radius filler 338 the continuous segments 342 of the composite tape 104 that form the transition portion of the initial ply 306.

In an example, folding support 352 is a cable, rope, rod, or other suitable member suspended above composite panel 302 and extending along (e.g., parallel to) longitudinal axis 324 of composite stiffener 308. After the folded portion 354 is formed, the folded support 352 is removed. In an example, the folding supports 352 are withdrawn from between the web portion 310 of the initial ply 306 and the complementary web portion 312 (FIG. 22) of the initial ply 306.

In an example, once the formation of the composite reinforcement 308 is complete (e.g., after all subsequent plies of the composite tape 104 are arranged to form all subsequent layers of the composite reinforcement 308), the folding of the web 328 may form the distal end 362 (fig. 2-4) of the web 328. In an example, another radius filler (not shown) may be located within the small space formed by the folding support 352 between the web portion 310 of the initial ply 306 and the supplemental web portion 312 (FIG. 22) of the initial ply 306. In an example, once the formation of the composite stiffener 308 is complete, the fold of the web 328 may be trimmed to form the distal end 362 of the web 328.

Referring to fig. 22, after formation of the folded portion 354, the back plate 106 is selectively positioned to support the web portion 310 such that the continuous segments 342 of the composite strip 104 can be disposed on the web portion 310 to form the supplemental web portion 312. In an example, the back plate 106 is selectively positioned such that the plate surface 146 is in contact with the second surface 350 of the web portion 310 of the initial ply 306. The continuous segment 342 of the composite tape 104 is disposed by the delivery head 114 on the first surface 316 of the web portion 310 of the initial ply 306, which serves as the placement surface 222, and compressed by the compaction roller 124. The back plate 106 supports the web portion 310 and reacts the placement force 112 applied to the web portion 310 of the initial ply 306 by the delivery head 114.

In an example, the backplate 106 is selectively moved (e.g., linearly and/or rotationally) relative to (e.g., along or parallel to an X-axis and/or a Z-axis of the environmental reference frame 340 and/or a Y-axis about the environmental reference frame 340). In an example, back plate 106 is selectively rotationally moved about at least one of first rotational axis of motion 162 and second rotational axis of motion 166 to orient back plate 106 with respect to web portion 310 of initial ply 306 at an angular orientation corresponding to the angular orientation of web portion 310 of initial ply 306 (e.g., web 328 of composite stiffener 308). In an example, the back plate 106 is selectively moved linearly along the first linear axis of motion 168 toward the delivery head 114 to position the back plate 106 in contact with the second surface 350 of the web portion 310 of the initial ply 306. In an example, the back plate 106 is selectively moved linearly along the third linear axis of motion 172 such that the arms 178 of the drive assembly 174 do not interfere with the portion of the composite stiffener 308 being laid or that has been previously laid.

Referring to fig. 16, in an example, the method 1000 includes the step of laying up the continuous segments 342 of the composite tape 104 on the web portions 310 of the initial plies 306 supported by the back plate 106 with the delivery head 114 to form supplemental web portions 312 of the initial plies 306 of the composite stiffener 308 (block 1020). In an example, the supplemental web portion 312 (fig. 22) of the initial plies 306 forms a portion (e.g., a layer) of the web 328 (fig. 2-4) of the composite stiffener 308. For example, the supplemental web portion 312 of the initial ply 306 is part of a first web layer of the web 328 (FIG. 10).

In an example, as illustrated in fig. 22, the delivery head 114 is selectively moved (e.g., positions and/or orientations determined) relative to the composite face sheet 302, back sheet 106, and web portions 310 of the initial plies 306 to arrange the continuous segments 342 of the composite tape 104 on the web portions 310 of the initial plies 306 to form supplemental web portions 312 of the initial plies 306 of the composite stiffeners 308. For example, the delivery head 114 is moved linearly relative to the environmental reference frame 340 (e.g., along or parallel to the Z-axis of the environmental reference frame 340) along a placement path indicated by directional arrow 256 such that a continuous segment 342 of the composite tape 104 is placed by the delivery head 114 on the first surface 316 of the web portion 310 of the initial ply 306 serving as the placement surface 222. As the composite strip 104 is arranged, the compaction roller 124 immediately or subsequently compresses the continuous segment 342 of the composite strip 104.

As the delivery head 114 is moved relative to the back plate 106 and the web portion 310 of the initial ply 306 to arrange the continuous segments 342 of the composite tape 104 on the back plate 106 to form the supplemental web portion 312 of the initial ply 306 of the composite reinforcement 308, a sufficient length of the composite tape 104 is fed from the delivery head 114 so as not to deform the web portion 310 of the initial ply 306.

Referring to fig. 16, in an example, the method 1000 includes the step of supporting the web portions 310 of the initial plies 306 with the back plate 106 while the composite tape 104 is laid up on the web portions 310 of the initial plies 306 to form supplemental web portions 312 of the initial plies 306 of the composite reinforcement 308 (block 1022).

When the continuous segments 342 of the composite tape 104 are laid down on the web portion 310 of the initial ply 306 to form the supplemental web portion 312 of the initial ply 306, supporting the web portion 310 of the initial ply 306 with the back plate 106 reacts to the placement force 112 applied to the web portion 310 of the initial ply 306 by the delivery head 114 by transferring the placement force 112 from the back plate 106 through the reaction structure 226 and back to the delivery head 114.

In an example, the method 1000 includes the steps of fixing the position of the back plate 106 relative to the web portion 310 of the initial plies 306 of the composite reinforcement 308 and moving the delivery head 114 relative to the back plate 106 while the composite tape 104 is laid up on the web portion 310 of the initial plies 306 to form a supplemental web portion 312 of the initial plies 306 of the composite reinforcement 308.

Referring to fig. 22, in an example, the position of back sheet 106 relative to composite panel 302, web portion 310 of initial plies 306, and radius fillers 338 is fixed as back sheet 106 is selectively positioned for placement of composite tape 104. The delivery head 114 is moved relative to the composite face sheet 302, radius filler 338, back sheet 106, and web portion 310 of the initial ply 306 to dispose the composite tape 104 on the web portion 310 of the initial ply 306 to form a portion of the composite stiffener 308. In an example, back plate 106 is fixed relative to environmental reference frame 340 and delivery head 114 is moved relative to environmental reference frame 340 along a placement path indicated by directional arrow 256 to place continuous segments 342 of composite tape 104 on web portions 310 of initial plies 306 to form supplemental web portions 312 of composite stiffeners 308. Thus, during placement of the composite tape 104 on the web portion 310 of the initial ply 306 to form a supplemental web portion 312 of the initial ply 306, the delivery head 114 moves relative to the back plate 106, which back plate 106 remains stationary and in a fixed position relative to the environmental reference frame 340. Drive assembly 174, which reacts to movement of delivery head 114, maintains a fixed position of backing plate 106 and effects movement of delivery head 114 relative to backing plate 106.

In an example, the method 1000 includes the step of laying up the continuous segments 342 of the composite tape 104 over the radius filler 338 with the delivery head 114 to form the supplemental transition portions of the initial plies 306 of the composite reinforcement 308. In an example, the supplemental transition portion of the initial plies 306 forms a portion (e.g., a layer) of the transition 364 (fig. 2-4) of the composite reinforcement 308.

In an example, the delivery head 114 is then selectively moved relative to the web portion 310 of the initial ply 306 and the radius filler 338 to transition from the web portion 310 to the radius filler 338 and to dispose the continuous segment 342 of the composite tape 104 on the radius filler 338. For example, delivery head 114 is selectively moved (linearly and/or rotationally) relative to environmental reference frame 340 (e.g., along or parallel to a Z-axis and/or X-axis of environmental reference frame 340 and/or a Y-axis about environmental reference frame 340) such that continuous section 342 of composite strip 104 is placed by delivery head 114 on radius filler 338, which serves as placement surface 222. As the composite strip 104 is arranged, the compaction roller 124 immediately or subsequently compresses the continuous segment 342 of the composite strip 104.

When the delivery head 114 transitions from disposing the composite tape 104 on the web portion 310 of the initial ply 306 to disposing the composite tape 104 on the radius filler 338, a sufficient length of the composite tape 104 is fed from the delivery head 114 so as not to lift or otherwise pull the continuous segments 342 of the composite tape 104 forming the web portion 310 of the initial ply 306 from the first surface 316 of the web portion 310 of the initial ply 306.

Referring to fig. 16, in an example, the method 1000 includes the step of laying up the continuous segments 342 of the composite tape 104 on the composite panel 302 with the delivery head 114 to form the supplemental flange portions 314 of the initial plies 306 of the composite reinforcement 308 (block 1024). In an example, the supplemental flange portion 314 of the initial ply 306 (fig. 23) forms a portion (e.g., a layer) of the flange 332 (fig. 2 and 3) of the composite stiffener 308. For example, supplemental flange portion 314 of initial laminate 306 is part of first flange 372 of flange 332 (FIG. 10).

Referring to fig. 23, in an example, the delivery head 114 is then selectively moved relative to the web portion 310 and the radius filler 338 of the initial ply 306 to transition from the radius filler 338 to the composite panel 302 and to arrange the continuous segments 342 of the composite tape 104 on the composite panel 302 to form the supplemental flange portion 314 of the initial ply 306. In an example, the supplemental flange portion 314 of the initial ply 306 is positioned perpendicular to the supplemental web portion 312 of the initial ply 306.

In an example, the delivery head 114 is then selectively moved relative to the composite panel 302 to arrange the continuous segments 342 of the composite tape 104 on the composite panel 302 to form the supplemental flange portions 314 of the initial plies 306 of the composite stiffener 308. For example, delivery head 114 is moved linearly relative to environmental reference frame 340 (e.g., along or parallel to the X-axis of environmental reference frame 340) along a placement path indicated by directional arrow 258 such that a continuous segment 342 of composite tape 104 is placed by delivery head 114 against inner surface 330 of composite panel 302 serving as placement surface 222. As the composite strip 104 is arranged, the compaction roller 124 immediately or subsequently compresses the continuous segment 342 of the composite strip 104.

Referring to fig. 16, in an example, the method 1000 includes the step of cutting the continuous segment 342 of the composite tape 104 to terminate the initial ply 306 (block 1026). In various examples, the manner in which the continuous segments 342 of the composite strip 104 are cut may depend, for example, on the particular lay-up configuration of the composite stiffeners 308.

In an example, cutting the continuous segments 342 of the composite strip 104 after placing the continuous segments 342 of the composite strip 104 to form the flange portion 304 and the web portion 310 of the initial ply 306 forms the basic structure of the composite stiffener 308 having an L-shaped cross-section.

In some examples, method 1000 may further include the step of laying up additional continuous segments of composite strip 104 on web portion 310 to form supplemental web portion 312 and/or supplemental flange portion 314. In one example, cutting additional segments of the composite strip 104 after placement to form the supplemental web portion 312 forms the basic structure of the composite reinforcement 308 having a back-to-back L-shaped cross-section.

In an example, cutting the continuous segments 342 of the composite strip 104 after placing the continuous segments 342 of the composite strip 104 to form the flange portions 304, the web portions 310, the supplemental web portions 312, and the supplemental flange portions 314 of the initial plies 306 forms the basic structure of the composite stiffener 308 having a T-shaped cross-section.

In an example, the method 1000 includes the step of laying up a plurality of subsequent continuous segments 344 of the composite tape 104 on the initial ply 306 with the delivery head 114 to form a plurality of subsequent plies 320 of the composite reinforcement 308 (block 1028). In an example, each of the subsequent plies 320 is one of the plies 334 of the composite tape 104 (fig. 2-4) that is laid up to form the composite reinforcement 308.

Referring to fig. 17-30, in accordance with the disclosed method 1000, the steps of laying up the continuous segments 342 of the composite tape 104 to form the initial ply 306d of the composite reinforcement 308 and laying up the subsequent continuous segments 344 of the composite tape 104 on the initial ply 306 to form the subsequent ply 320 of the composite reinforcement 308 may be performed in a variety of different ways to achieve the desired configuration of the ply 334 (fig. 2-4) of the composite tape 104.

In an example, the composite tape 104 includes a fiber orientation. When forming the composite reinforcement 308, the continuous segments of the composite tape 104 may be placed such that each of the plies 334 of the composite reinforcement 308 has a predetermined fiber orientation angle relative to the longitudinal axis 324 of the composite reinforcement 308. In some examples, the composite stiffener 308 is one of a symmetric laminate, an anti-symmetric laminate, an asymmetric laminate, an isotropic laminate, a unidirectional laminate, an angle ply laminate, a cross ply laminate, or the like.

In an example, the continuous segments of the composite tape 104 may be placed such that one or more of the plies 334 of the composite reinforcement 308 have a fiber orientation angle of 90 degrees relative to the longitudinal axis 324 of the composite reinforcement 308. In an example, the continuous segments of the composite tape 104 may be placed such that one or more of the plies 334 of the composite reinforcement 308 have a fiber orientation angle of 45 degrees relative to the longitudinal axis 324 of the composite reinforcement 308. In an example, the continuous segments of the composite tape 104 may be placed such that one or more of the plies 334 of the composite reinforcement 308 have a fiber orientation angle of 0 degrees relative to the longitudinal axis 324 of the composite reinforcement 308. In an example, the continuous segments of the composite tape 104 may be placed such that one or more of the plies 334 of the composite reinforcement 308 have a fiber orientation angle of 30 degrees relative to the longitudinal axis 324 of the composite reinforcement 308. In an example, the continuous segments of the composite tape 104 may be placed such that one or more of the plies 334 of the composite reinforcement 308 have a fiber orientation angle of 60 degrees relative to the longitudinal axis 324 of the composite reinforcement 308.

The fiber orientation angle of each of the plies 334 of the composite reinforcement 308 may depend on the angular orientation of the delivery head 114 of the tape placement machine 102 and the angular orientation of the placement path followed by the delivery head 114 when placing the composite tape 104. In an example, when the placement path of delivery head 114 passes through longitudinal axis 324 of composite stiffener 308 at a 90 degree angle or perpendicular to longitudinal axis 324 of composite stiffener 308, plies 334 of composite stiffener 308 have a 90 degree angle of fiber orientation. In an example, when the placement path of delivery head 114 passes through longitudinal axis 324 of composite stiffener 308 at an angle of 45 degrees, 30 degrees, or 60 degrees, or oblique to the longitudinal axis of composite stiffener 308, respectively, plies 334 of composite stiffener 308 have a fiber orientation angle of 45 degrees, 30 degrees, or 60 degrees. In an example, when the placement path of delivery head 114 passes through longitudinal axis 324 of composite stiffener 308 at an angle of 0 degrees or parallel to the longitudinal axis of composite stiffener 308, plies 334 of composite stiffener 308 have a fiber orientation angle of 0 degrees.

Fig. 10, 31, and 32 schematically illustrate examples of composite stiffeners 308 in which the initial plies 386 or initial plies of plies 334 (fig. 2-4) of the composite stiffener 308 have a fiber orientation angle of 90 degrees. Each of the successive segments of composite tape 104 is arranged by delivery head 114 along a placement path oriented at a 90 degree angle relative to longitudinal axis 324 of composite stiffener 308.

Fig. 10 schematically illustrates an example of a composite reinforcement 308 in which a subsequent layer 388 or subsequent plies of plies 334 (fig. 2-4) of the composite reinforcement have a fiber orientation angle of 90 degrees. Each of the successive segments of composite tape 104 is arranged by delivery head 114 along an associated placement path indicated by an associated one of

directional arrows

110, 234, 252, 254 oriented at a 90 degree angle relative to longitudinal axis 324 of composite stiffener 308. It will be appreciated that as the composite tape 104 is arranged, the compaction roller 124 of the delivery head 114 follows the course of the placement path indicated by the associated one of the

directional arrows

110, 234, 252, 254.

Fig. 31 schematically illustrates an example of a composite reinforcement 308 in which a subsequent layer 388 or subsequent plies of plies 334 (fig. 2-4) of the composite reinforcement have fiber orientation angles that are oblique (e.g., 45 degrees). Each of the successive segments of composite tape 104 is arranged by delivery head 114 along an associated placement path indicated by an associated one of

directional arrows

260, 262, 264, 266 oriented at an oblique (e.g., 45 degree) angle relative to longitudinal axis 324 of composite stiffener 308. It should be appreciated that as the composite tape 104 is arranged, the compaction roller 124 of the delivery head 114 follows the path of the placement path indicated by the associated one of the

directional arrows

260, 262, 264, 266.

Fig. 32 schematically illustrates an example of a composite reinforcement 308 in which a subsequent layer 388 or subsequent plies of a ply 334 (fig. 2-4) of the composite reinforcement have a fiber orientation angle of 0 degrees. Each of the successive segments of composite tape 104 is arranged by delivery head 114 along an associated placement path indicated by an associated one of

directional arrows

268, 270, 272 oriented at an angle of 0 degrees relative to longitudinal axis 324 of composite stiffener 308. It will be appreciated that as the composite tape 104 is arranged, the compaction roller 124 of the delivery head 114 follows the course of the placement path indicated by the associated one of the

directional arrows

268, 270, 272.

Fig. 17-23 schematically illustrate the placement of successive segments 342 of the composite strip 104 to form the initial plies 306 of the composite reinforcement 308. In the illustrative example, delivery head 114 follows a placement path that is one of perpendicular (90 degrees) to longitudinal axis 324 of composite stiffener 308 or oblique (30 degrees, 45 degrees, 60 degrees) to longitudinal axis 324 of composite stiffener 308.

24-28 schematically illustrate placing one of the subsequent continuous segments 344 of the composite tape 104 to form one of the subsequent plies 320 of the composite reinforcement 308. In the illustrative example, delivery head 114 follows a placement path that is one of perpendicular (90 degrees) to longitudinal axis 324 of composite stiffener 308 or oblique (30 degrees, 45 degrees, 60 degrees) to the longitudinal axis of composite stiffener 308.

Fig. 29 and 30 schematically illustrate placing one of the subsequent continuous segments 344 of the composite tape 104 to form one of the subsequent plies 320 of the composite reinforcement 308. In the illustrative example, the delivery head 114 follows a placement path parallel (0 degrees) to the longitudinal axis 324 of the composite stiffener 308.

Referring to fig. 24, in an example, the method 1000 includes the step of laying up a first of the subsequent continuous segments 344 of the composite tape 104 on the flange portion 304 of the initial ply 306 of the composite reinforcement 308 with the delivery head 114 to form the flange portion 318 of the first of the subsequent plies 320 of the composite reinforcement 308.

Referring to FIG. 25, in an example, the method 1000 includes the step of positioning the back plate 106 behind the supplemental web portion 312 of the initial plies 306. In an example, the method 1000 includes the step of laying up a first of the subsequent continuous segments 344 of the composite tape 104 on the web portion 310 of the initial ply 306 supported by the back plate 106 with the delivery head 114 to form a web portion 322 of a first of the subsequent plies 320 of the composite stiffener 308.

Referring to FIG. 26, in an example, method 1000 includes the step of positioning back plate 106 behind web portion 322 of a first of the subsequent plies 320.

Referring to fig. 27, in an example, the method 1000 includes the step of laying up a first of the subsequent continuous segments 344 of the composite tape 104 on the supplemental web portion 312 of the initial ply 306 supported by the back plate 106 with the delivery head 114 to form a supplemental web portion 326 of a first of the subsequent plies 320 of the composite stiffener 308.

Referring to fig. 28, in an example, the method 1000 includes the step of laying up a first of the subsequent continuous segments 344 of the composite tape 104 on the supplemental flange portion 314 of the initial ply 306 of the composite reinforcement 308 with the delivery head 114 to form a supplemental flange portion 346 of the first of the subsequent plies 320 of the composite reinforcement 308.

In an example, the method 1000 includes the step of cutting subsequent consecutive segments 344 of the composite tape 104 to terminate a first of the subsequent plies 320. In an example, cutting subsequent continuous segments 344 of the composite strip 104 after placing the subsequent continuous segments 344 to form the flange portion 318, the web portion 322, the supplemental web portion 326, and the supplemental flange portion 346 of the subsequent ply 320 further forms the basic structure of the composite stiffener 308 having a T-shaped cross-section. In an example, cutting the subsequent continuous segment 344 of the composite strip 104 after placing the subsequent continuous segment 344 of the composite strip 104 to form the flange portion 318 and the web portion 322 of the subsequent ply 320 further forms the basic structure of the composite stiffener 308 having an L-shaped cross-section.

Referring to fig. 29, in an example, the method 1000 includes the step of laying up a first of the subsequent continuous segments 344 of the composite tape 104 on the flange portion 304 of the initial ply 306 of the composite reinforcement 308 with the delivery head 114 to form the flange portion 318 of the first of the subsequent plies 320 of the composite reinforcement 308.

Referring to FIG. 30, in one example, the method 1000 includes the step of positioning the back plate 106 behind the supplemental web portion 312 of the initial plies 306. In an example, the method 1000 includes the step of laying up a second of the subsequent continuous segments 344 of the composite tape 104 on the web portion 310 of the initial ply 306 supported by the back plate 106 with the delivery head 114 to form the web portion 322 of the first of the subsequent plies 320 of the composite stiffener 308.

In an example, the method 1000 includes the step of laying up a third of the subsequent continuous segments 344 of the composite tape 104 on the supplemental flange portion 314 of the initial ply 306 of the composite reinforcement 308 with the delivery head 114 to form a supplemental flange portion 346 of a third of the subsequent plies 320 of the first composite reinforcement 308.

In one example, method 1000 includes the step of positioning back plate 106 behind web portion 322 of a first of the subsequent plies 320. In an example, the method 1000 includes the step of laying up a fourth of the subsequent consecutive segments 344 of the composite tape 104 on the supplemental web portion 312 of the initial ply 306 supported by the back plate 106 with the delivery head 114 to form a supplemental web portion 326 of a first of the subsequent plies 320 of the composite stiffener 308.

In an example, the method 1000 includes the step of cutting subsequent consecutive segments 344 of the composite tape 104 to terminate each of the first, second, third, and fourth of the subsequent plies 320.

In an example, the method 1000 includes the step of laying up additional ones of the subsequent continuous segments 344 of the composite tape 104 with the delivery head 114 to form additional ones of the subsequent plies 320 of the composite reinforcement 308.

It should be appreciated that the operational steps, and more particularly the selective positioning and moving steps of delivery head 114 and/or backing plate 106 relative to one another, may be performed as a continuous operation or in a step-wise manner.

Referring to fig. 5, in some examples, the device 100 includes one or more sensors 274. Sensors 274 are configured to determine the relative position (e.g., position and/or orientation) and relative movement (e.g., linear and/or rotational) of delivery head 114 and/or backing plate 106. In some examples, sensor 274 generates information related to the position of delivery head 114, such as in response to selective movement of delivery head 114 as controlled by movement system 130. In some examples, the sensors 274 generate information related to the orientation of the backing plate 106, such as in response to selective movement of the backing plate 106 controlled by the drive assembly 174. The sensors 274 may include any one or more of proximity sensors, position sensors, accelerometers, Infrared (IR) sensors, light sensors, ultrasonic sensors, and any other type of electronic sensor.

In some examples, the apparatus 100 includes one or more encoders 276. Encoder 276 is configured to convert information related to the position (e.g., position and/or orientation) and relative movement (e.g., linear and/or rotational) of delivery head 114 and/or back plate 106 into a format or code that can be used by controller 132 and/or computer system 238. In an example, encoder 276 converts information related to the position of delivery head 114, such as provided by sensor 274 for use by controller 132 and/or computer system 238, to selectively control movement system 130. In an example, the encoder 276 converts information related to the position of the backing plate 106, such as provided by the sensor 274 for use by the controller 132 and/or the computer system 238, to selectively control the drive assembly 174. The encoder 276 may include any one or more of devices, circuits, transducers (e.g., rotary and/or linear encoders), and software programs and/or algorithms stored, for example, in the memory 134 and executed by one or more processors of the computer system 238.

In some examples, controller 132 and/or computer system 238 utilize computer numerical control to automate and selectively control the orientation and movement of delivery head 114 and backing plate 106 when composite tape 104 is disposed. The computer numerical control is operable to execute a pre-programmed sequence of machine control commands.

Referring to fig. 33, an example of a method 2000 for reacting a placement force 112 applied by a tape placement machine 102 that lays up composite tape 104, such as when forming a composite structure 300, is also disclosed.

In one example, method 2000 includes the step of coupling backing plate 106 to delivery head 114 of tape placement machine 102 (block 2002). In one example, method 2000 includes the step of positioning backing plate 106 with respect to delivery head 114 (block 2004). In an example, method 2000 includes the step of applying placement force 112 by delivery head 114 while laying composite tape 104 on backing sheet 106 with delivery head 114 (block 2006). In an example, the method 2000 includes the step of reacting the placement force 112 by the backing plate 106 when the composite tape 104 is laid on the backing plate 106 using the delivery head 114 (block 2008).

In an example, compaction roller 124 exerts a placement force 112 (e.g., a compaction force) on backing plate 106, which backing plate 106 is linked to delivery head 114 via reaction structure 226.

In one example, method 2000 includes the step of fixing the position of backplane 106. Fixing the position of the backplate 106 enables the backplate 106 to react the placement forces. In one example, method 2000 includes the step of moving delivery head 114 relative to backing plate 106 while laying composite tape 104 on backing plate 106. Moving delivery head 114 along backing plate 106 and compressing composite tape 104 as composite tape 104 is laid down generates a placement force.

Referring to fig. 34, a method 3000 for making the composite structure 300 is also disclosed. In an example, the method 3000 includes the step of laying up the flange portion 304, the web portion 310, the supplemental web portion 312, and the supplemental flange portion 314 in successive segments 342 of the composite tape 104 with the tape placement machine 102 to form the composite stiffeners 308 on the composite panel 302 while reacting the placement force 112 applied to the web portion 310 and the supplemental web portion 312 by the compaction rollers 124 of the tape placement machine 102 back into the tape placement machine 102 (block 3002).

In an example, method 3000 includes the step of folding the continuous segment 342 of the composite strip 104 to transition from the web portion 310 to the supplemental web portion 312 (block 3004).

In an example, method 3000 further includes the step of laying up, with tape placement machine 102, continuous segments 342 of composite tape 104 over radius filler 338 located on composite panel 302 as transitioning from flange portion 304 to web portion 310 and as transitioning from supplemental web portion 312 to supplemental flange portion 314 (block 3006).

Referring to fig. 35, a method 4000 for making a composite structure 300 including a composite panel 302 and an integral composite stiffener 308 is also disclosed. In one example, the method 4000 includes the step of laying up the composite panel 302 on the mandrel 116 using the tape placement machine 102 (block 4002). In an example, the method 4000 includes the step of positioning a backing plate 106 coupled to a delivery head 114 of the tape placement machine 102 to support a portion of the web 328 of the composite stiffener 308 (block 4004). In an example, method 4000 includes the step of laying the portion of web 328 on back plate 106 with back plate 106 reacting placement force 112 into delivery head 114 (block 4006).

In an example, method 4000 includes the step of repositioning back plate 106 to an opposite side of the portion of web 328 to support a supplemental portion of web 328 of composite stiffener 308 (block 4008). In an example, method 4000 includes the step of laying up a supplemental portion of web 328 over the portion of web 328 with backing plate 106 reacting placement force 112 into delivery head 114 (block 4010).

According to the method 4000, in one example, the portion of the web 328 and the supplemental portion of the web 328 are formed from the continuous segment 342 of the composite strip 104. In an example, the method 4000 includes the step of supporting the continuous segment 342 of the composite tape 104 with the delivery head 114 after forming the portion of the web 328. In an example, the method 4000 includes the step of folding the continuous segment 342 of the composite strip 104 to transition from the portion of the web 328 to the supplemental portion of the web 328.

A portion of an aircraft 1200 assembled according to method 1000 is also disclosed. A portion of an aircraft 1200 assembled according to method 2000 is also disclosed. A portion of an aircraft 1200 assembled according to method 3000 is also disclosed. A portion of an aircraft 1200 assembled according to method 4000 is also disclosed.

In an example, the disclosed apparatus 100 for making a composite structure 300 includes a tape placement machine 102, the tape placement machine 102 including a delivery head 114 configured to arrange a composite tape 104. The apparatus 100 also includes a backing plate 106, the backing plate 106 being coupled to the delivery head 114 and selectively positioned relative to the delivery head 114 to react the placement force 112 applied by the tape placement machine 102 when the composite tape 104 is being placed.

In an example, the apparatus 100 for making the composite structure 300 includes a mandrel 116 to support the formation of the composite panel 302 of the composite structure 300. The apparatus 100 also includes a tape placement machine 102, the tape placement machine 102 including a delivery head 114 and a compaction roller 124, the delivery head 114 configured to dispose the composite tape 104, the compaction roller 124 configured to apply the placement force 112 when disposing the composite tape 104. Apparatus 100 also includes a backing plate 106, the backing plate 106 coupled to the delivery head 114 and selectively movable relative to the delivery head 114 to support formation of composite stiffeners 308 extending from composite panel 302. When delivery head 114 places composite tape 104 on backing plate 106, backing plate 106 reacts placement force 112 back to delivery head 114.

A method for making a portion of the aircraft 1200 using the apparatus 100 is also disclosed.

In accordance with the apparatus 100 and examples of the

methods

1000, 2000, 3000, and 4000, a composite structure 300 fabricated using a tape placement machine 102 including a delivery head 114 and a backing plate 106 movably coupled with the delivery head 114 is also disclosed. In an example, composite structure 300 includes composite face sheet 302 and composite stiffeners 308, the composite stiffeners 308 being formed in situ on composite face sheet 302 and including webs 328 formed on back sheet 106 and extending from composite face sheet 302.

In an example, web 328 of composite stiffener 308 includes a plurality of plies 334 of composite tape 104 arranged on backing plate 106 by delivery head 114. Each of the plies 334 partially forms a web portion 310 of the web 328 and a complementary web portion 312 of the web 328. At least some of the plies 334 are shared by the composite stiffener 308 and the composite panel 302.

According to examples of

methods

1000, 2000, 3000, and 4000 disclosed herein, in some examples, multiple apparatuses 100 or apparatuses 100 including multiple delivery heads 114 each having a backing plate 106 and a reaction structure 226 associated therewith may be cooperatively used to fabricate a composite structure 300. In an example, the plurality of delivery heads 114 substantially form the composite panel 302, for example, by arranging a plurality of layers of the composite tape 104 on the mandrel 116 (fig. 7). After composite face sheet 302 is substantially formed, multiple delivery heads 114 are simultaneously operated to form composite stiffeners 308, e.g., disposed on composite face sheet 302 and backing sheet 106 (fig. 8) by multiple layers of composite tape 104, and the formation of composite face sheet 302 is completed.

Examples of the apparatus 100, composite structure 300, and

methods

1000, 2000, 3000, and 4000 disclosed herein may be applied in a wide variety of possible applications, particularly in the transportation industry (including, for example, aerospace applications). Referring now to fig. 33 and 34, examples of the apparatus 100, composite structure 300, and

methods

1000, 2000, 3000, and 4000 may be used in the context of an aircraft manufacturing and service method 1100, as shown in the flowchart of fig. 36, and an aircraft 1200, as shown in fig. 37. The aircraft applications of the disclosed examples may include the formation of wings, airfoils, body panels, or other composite structures used in the manufacture of aircraft.

As shown in fig. 36, during pre-production, illustrative method 1100 may include specification and design of aircraft 1200 (block 1102) and material procurement (block 1104). During production of the aircraft 1200, aircraft 1200 component and subassembly manufacturing (block 1106) and system integration (block 1108) may occur. Thereafter, the aircraft 1200 may undergo acceptance and delivery (block 1110) to bring it into service (block 1112). Routine maintenance and service (block 1114) may include modification, reconfiguration, refurbishment, and the like of one or more systems of the aircraft 1200. Examples of the disclosed apparatus 100, composite structure 300, and

methods

1000, 2000, and 3000 may form part of, or may be used or implemented with, at least component and subassembly manufacturing (block 1106), system integration (block 1108), and routine maintenance and service (block 1114).

Each of the processes of the illustrative method 1100 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For purposes of illustration, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major-system subcontractors; the third party may include, but is not limited to, any number of sellers, subcontractors, and suppliers; and the operator may be an airline, leasing company, military entity, service organization, and so forth.

As shown in fig. 37, an aircraft 1200 produced by the illustrative method 1100 may include a fuselage 1202, a plurality of high-level systems 1204, and an interior 1206. Other examples of high-level systems 1204 include one or more of propulsion system 1208, electrical system 1210, hydraulic system 1212, and environmental system 1214. Any number of other systems may be included. The disclosed examples of apparatus 100, composite structure 300, and

methods

1000, 2000, and 3000 may be used to fabricate portions of fuselage 1202 and interior 1206.

The examples of the apparatus 100 and methods 1000 and 2000 shown or described herein may be employed during any one or more of the stages of the manufacturing and service method 1100 shown in the flowchart illustrated by fig. 36. For example, components or subassemblies corresponding to the fabrication of components and subassemblies (block 1106), such as those comprising composite structure 300, may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft 1200 is in service (block 1112). Also, during the production phase (blocks 1108 and 1110), one or more examples of the apparatus 100, methods 1000 and 2000, or a combination thereof may be used. Similarly, for example, without limitation, one or more examples of apparatus 100, methods 1000 and 2000, or a combination thereof may be used while the aircraft 1200 is in service (block 1112) and during a maintenance and service phase (block 1114).

Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Thus, in addition to aircraft, the principles disclosed herein may be applied to other vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.).

Reference herein to an "example" means that one or more features, structures, elements, components, characteristics, and/or operational steps described in connection with the example are included in at least one embodiment and/or implementation of the subject matter of this disclosure. Thus, the phrase "example" and similar language throughout this disclosure may, but do not necessarily, refer to the same example. Further, characterizing the subject matter of any one example may, but need not, include characterizing the subject matter of any other example.

As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is actually capable of performing the specified function without any change, and does not merely have the possibility of performing the specified function upon further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is specifically selected, formed, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, "configured to" means an existing characteristic of a system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform a specified function without further modification. For purposes of this disclosure, a system, device, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "adapted to" and/or "operable to" perform that function.

Unless otherwise indicated, the terms "first," "second," and the like are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the articles to which such terms refer. In addition, reference to "second" items does not require or hinder the presence of lower numbered items (e.g., "first" items) and/or higher numbered items (e.g., "third" items).

As used herein, "coupled," "coupling," and similar terms refer to two or more elements being joined, fastened, connected, placed in communication, or otherwise associated with (e.g., mechanically, electrically, fluidically, optically, electromagnetically) one another. In various examples, elements may be directly or indirectly associated. As an example, element A may be directly associated with element B. As another example, element a may be indirectly associated with element B, e.g., via another element C. It should be understood that not all relationships between the various disclosed elements are necessarily represented. Thus, couplings other than those depicted in block diagrams may also exist.

As used herein, the word "at least one," when used with a list of items, means that different combinations of one or more of the listed items may be used and only one of each item in the list may be necessary. For example, "at least one of item a, item B, and item C" may include, for example, but not limited to, item a, or item a and item B. This example may also include item a, item B, and item C or item B and item C. In other examples, "at least one of" may be, for example, but not limited to, two of items a, one of items B, and ten of items C; four of items B and seven of items C; and other suitable combinations.

In fig. 5 and 37 mentioned above, the blocks may represent elements, components, and/or portions thereof, and the lines connecting the various elements and/or components, if any, may represent mechanical, electrical, fluidic, optical, electromagnetic and other couplings, and/or combinations thereof. Thus, connections other than those shown in the block diagrams may also be present. Dashed lines connecting blocks designating various elements and/or components, if any, represent functionally and purposely similar couplings to those represented by solid lines; however, the coupling indicated by the dotted line may be selectively provided or alternative examples may be involved. Similarly, elements and/or components indicated by dashed lines indicate alternative examples, if any. One or more elements shown in solid and/or dashed lines may be omitted from a particular example without departing from the scope of the disclosure. The dotted lines represent environmental elements (if any). Dummy (phantom) elements may also be shown for clarity. Those skilled in the art will appreciate that some of the features shown in fig. 5 may be combined in various ways without the need to include other features described in fig. 1, other figures, and/or the accompanying disclosure, even if such combinations are not expressly stated herein. Similarly, additional features not limited to the examples set forth may be combined with some or all of the features shown and described herein.

In the above-mentioned fig. 16 and 33-36, the blocks may represent operations and/or portions thereof, and the lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof. Blocks represented by dashed lines represent alternate operations and/or portions thereof. The dashed lines connecting the various blocks (if any) represent alternative dependencies of the operations or portions thereof. It is to be understood that not necessarily all dependencies between various disclosed operations are depicted. Fig. 16 and 33-36 and the accompanying disclosure describing the operations of the disclosed methods set forth herein should not be construed as necessarily determining the order in which the various operations are performed. More precisely, while an illustrative sequence is indicated, it should be understood that the sequence of operations may be modified as desired. Thus, modifications, additions, and/or deletions may be made to the illustrated operations, and some may be performed in a different order or concurrently. Moreover, those skilled in the art will recognize that not all of the operations described need be performed.

While various examples of the disclosed apparatus, composite structures, and methods have been shown and described, modifications may occur to those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A method (1000) for making a composite structure (300), the method (1000) comprising laying up continuous segments (342) of a composite tape (104) on a composite panel (302) with a delivery head (114) of a tape placement machine (102) to form a flange portion (304) of an initial ply (306) of a composite stiffener (308); positioning a backing plate (106) coupled to the delivery head (114) relative to the delivery head (114) and composite face plate (302); and further laying up the continuous segments (342) of the composite tape (104) onto the backing plate (106) with the delivery head (114) to form a web portion (310) of the initial plies (306) of the composite stiffener (308).

2. The method (1000) of claim 1, further comprising fixing a position of the backing plate (106) relative to the composite face plate (302); and moving the delivery head (114) relative to the backing plate (106) while laying up the continuous segments (342) of the composite tape (104) on the backing plate (106) to form the web portion (310) of the initial plies (306) of the composite stiffener (308).

3. The method (1000) of claim 1 or 2, further comprising repositioning the backing plate (106) to a side of the web portion (310) of the initial ply (306) opposite the delivery head (114); further laying up the continuous segments (342) of the composite tape (104) on the web portions (310) of the initial plies (306) supported by the backing plate (106) with the delivery head (114) to form supplemental web portions (312) of the initial plies (306) of the composite stiffener (308); and further laying up the continuous segment (342) of the composite tape (104) on the composite panel (302) with the delivery head (114) to form a supplemental flange portion (314) of the initial ply (306) of the composite stiffener (308), preferably

Further including folding the continuous segment (342) of the composite tape (104) to transition from the web portion (310) of the initial ply (306) to the supplemental web portion (312) of the initial ply (306).

4. The method (1000) of claim 3, further comprising fixing a position of the delivery head (114) relative to the composite panel (302) to support an orientation of the web portion (310) of the initial plies (306) of the composite stiffener (308); moving the backing plate (106) relative to the delivery head (114) to separate the backing plate (106) from a first surface (316) of the web portion (310) of the initial ply (306); moving the backing plate (106) relative to the delivery head (114) into contact with a second surface (350) of the web portion (310) of the initial ply (306), the second surface (350) of the web portion (310) of the initial ply (306) being opposite the first surface (316) of the web portion (310) of the initial ply (306); and supporting the web portion (310) of the initial lay-up (306) with the backing plate (106), preferably with the web portion (310) of the initial lay-up (306) when the composite tape (104) is laid over the web portion (310) of the initial lay-up (306) to form the complementary web portion (312) of the initial lay-up (306) of the composite stiffener (308)

Further comprising fixing the position of the backing plate (106) relative to the web portion (310) of the initial plies (306) of the composite stiffener (308); and moving the delivery head (114) relative to the backing plate (106) while laying up the continuous segments (342) of the composite tape (104) on the web portion (310) to form the supplemental web portion (312) of the initial plies (306) of the composite stiffener (308).

5. The method (1000) of claim 3 or 4, further comprising laying up a plurality of subsequent continuous segments (344) of the composite tape (104) on the initial ply (306) with the delivery head (114) to form a plurality of subsequent plies (320) of the composite reinforcement (308).

6. The method (1000) of claim 5, further comprising positioning the backing plate (106) behind the supplemental web portion (312) of the initial plies (306) of the composite stiffener (308); and laying up a first one of the subsequent continuous segments (344) of the composite tape (104) on the web portion (310) of the initial ply (306) of the composite stiffener (308) supported by the backing plate (106) with the delivery head (114) to form a web portion (322) of a first one of the subsequent plies (320) of the composite stiffener (308).

7. The method (1000) of claim 6, further comprising positioning the back plate (106) behind the web portion (310) of the initial plies (306) of the composite stiffener (308); and further laying up the first of the subsequent consecutive segments (344) of the composite tape (104) on the supplemental web portion (312) of the initial ply (306) supported by the backing plate (106) with the delivery head (114) to form a supplemental web portion (326) of the first of the subsequent plies (320) of the composite stiffener (308),

or

Further comprising positioning the back plate (106) behind the web portion (310) of the initial plies (306) of the composite stiffener (308); and laying up a second one of the subsequent continuous segments (344) of the composite tape (104) on the supplemental web portion (312) of the initial ply (306) supported by the backing plate (106) with the delivery head (114) to form a supplemental web portion (326) of the first one of the subsequent plies (320) of the composite stiffener (308).

8. The method (1000) of any of claims 5-7, further comprising laying up the composite panel (302) on a mandrel (116); and placing radius filler (338) on the composite panel (302) prior to laying up the composite tape (104) to form the composite stiffener (308).

9. An apparatus (100) for making a composite structure (300), the apparatus (100) comprising a tape placement machine (102), the tape placement machine (102) comprising a delivery head (114) configured to arrange a composite tape (104); and a backing plate (106), the backing plate (106) coupled to the delivery head (114) and selectively positioned relative to the delivery head (114) to react a placement force (112) applied by the tape placement machine (102) when the composite tape (104) is being placed.

10. The apparatus (100) of claim 9, further comprising a first linear axis of motion (168), and wherein the backing plate (106) is linearly movable relative to the delivery head (114) along the first linear axis of motion (168).

11. The apparatus (100) of claim 10, further comprising a first rotational axis of motion (162), and wherein the backing plate (106) is rotationally movable relative to the delivery head (114) about the first rotational axis of motion (162).

12. The apparatus (100) of claim 10, further comprising a second linear axis of motion (170), the second linear axis of motion (170) being perpendicular to the first linear axis of motion (168), and wherein the backing plate (106) is linearly movable relative to the delivery head (114) along the second linear axis of motion (170).

13. The apparatus (100) of claim 12, further comprising a third linear axis of motion (172), the third linear axis of motion (172) being perpendicular to the first and/or second linear axes of motion (170), and wherein the back plate (106) is linearly movable relative to the delivery head (114) along the third linear axis of motion (172).

14. The apparatus (100) of claim 11, further comprising a second rotational motion axis (164), the second rotational motion axis (164) being perpendicular to the first rotational motion axis (162), and wherein the back plate (106) is rotationally movable relative to the delivery head (114) about the second rotational motion axis (164), preferably

Further including a third rotational axis of motion (166), the third rotational axis of motion (166) being parallel to the first rotational axis of motion (162), and wherein the backing plate (106) is rotationally movable relative to the delivery head (114) about the third rotational axis of motion (166).

15. The apparatus (100) of any of claims 9-14, further comprising a reaction structure (226), the reaction structure (226) coupled to the delivery head (114) and the backing plate (106) and configured to transfer the placement force (112) from the backing plate (106) back to the delivery head (114); and a drive assembly (174) operably coupled with the reaction structure (226), the drive assembly (174) configured to linearly move the backing plate (106) relative to the delivery head (114) and rotationally move the backing plate (106) relative to the delivery head (114).

16. A method for making a part of an aircraft (1200) using the apparatus (100) according to any one of the preceding claims 9-15.