EP4107058A1

EP4107058A1 - A curved aerospace profile article and method of manufacture of the article

Info

Publication number: EP4107058A1
Application number: EP20919856.3A
Authority: EP
Inventors: Mikael Petersson; Adam STRANDBERG
Original assignee: Saab AB
Current assignee: Saab AB
Priority date: 2020-02-17
Filing date: 2020-02-17
Publication date: 2022-12-28
Also published as: WO2021167504A1; EP4107058A4

Abstract

The present invention regards a profile manufacturing tool assembly (1003) configured for manufacture of a curved aerospace profile article (101) and a method of manufacture of a curved aerospace profile article (101) made of fibre reinforced matrix material. A profile manufacturing tool assembly (1003) comprises a first tool device (1005) configured to form a curved openbeam profile workpiece (19); a second tool device (1022) configured to divide in longitudinal direction the curved openbeam profile workpiece (19) in at least a first and second profile (33, 35); a third tool device (1049) configured to join the first and second profile (33, 35) to each other for providing said curved aerospace profile article (101); a fourth tool device (1061) configured to cure the curved openbeam profile workpiece (19) or configured to cure the first and second profile (33, 35) prior said joining or after said joining and removing after the curing step the curved aerospace profile article (101) from the fourth tool device (1061).

Description

A curved aerospace profile article and method of manufacture of the article

TECHNICAL FIELD

The present invention relates to a method of forming curved aerospace profile articles made of fibre reinforced matrix material.

The present invention also relates to the forming of curved openbeam profile workpieces of matrix used for producing said curved aerospace profile articles.

Said curved aerospace profile articles may be curved J-profiles, l-profiles, C-profiles, or T- profiles having an inner flange of shorter longitudinal length than the longitudinal length of the opposite outer flange, or other profiles. The profile geometry of the curved aerospace profile article thus be T-formed with an inner strengthening and mounting flange extending laterally from the web.

The present invention also relates to a profile manufacturing tool assembly configured for manufacture of said curved aerospace profile articles made of fibre reinforced matrix material.

The present invention also relates to a production line for the manufacture of said curved aerospace profile articles.

The present invention also relates to a data medium configured to control said method.

The present invention also relates to a data medium product storing said data medium configured to control said method of forming said curved aerospace profile articles.

The present invention may concern the industry manufacturing such curved openbeam profile workpieces in purpose to be used for producing said curved aerospace profile articles.

The curved aerospace profile articles may be used as structural frames or spars or beams in aerospace cargo doors, aerospace passenger doors, fuselages, wings etc.

The present invention especially may concern the aerospace industry producing integrated matrix composite parts of multi-profile structures comprising such curved aerospace profile articles.

The invention also may relate to a method of forming a fibre reinforced matrix aerospace composite part, such as an aerospace door or other aerospace structures. BACKGROUND

When manufacturing curved aerospace profile articles, there is a challenge to form, in an easy and time-saving way, the pre-preg or preform material comprising reinforcing fibres into said profiles having inner and outer flanges. The challenge is to form the material in an optimal way without generating any wrinkles mainly between the flanges and web portions.

For example, the forming of curved aerospace profile articles (e.g. curved J-profiles, C- profiles, l-profiles, L-profiles, T-profiles, T-profiles with opposite flange, etc.) involves high labour costs and time efforts as manual work is required, for a step-by step forming of each layer of pre-preg material with reinforcement fibres or plies of fibres of preform material, for avoiding wrinkles in inner and outer radii between the flanges and the web of the profiles.

Outside positioned reinforcing fibres are subjected to tension and inside positioned reinforcing fibres are subjected to compression during forming, which means that prior art methods of manufacture of such profiles are labour intensive as each layer of reinforcement fibres or plies of fibres must be conformed over the forming surface of the forming tool by hand.

SUMMARY OF THE INVENTION

There is an object to provide a time saving and cost-effective method of forming curved aerospace profile articles made of fibre reinforced matrix material.

There is an object to provide a time saving and cost-effective method of forming a curved aerospace profile article made of fibre reinforced matrix material, which profile article comprises an outer flange extending a longer distance in longitudinal direction than an inner flange of the profile article.

There is an object to provide automatization of forming curved aerospace profile articles made of fibre reinforced matrix material.

There is an object to provide a curved aerospace profile article in a cost-effective way in view of the reduction of wrinkles of the pre-preg material or preform material in inner and outer radii of the curved aerospace profile article.

There is an object to provide a cost-efficient production of curved aerospace profile articles and/or integrated matrix composite parts of multi-profile aerospace structures. There is an object to provide a profile manufacturing tool assembly for cost-effective production of curved aerospace profile articles.

There is an object to provide a profile manufacturing tool assembly that can be used cost- effective in a production line configured to produce curved aerospace profile articles.

There is an object to provide a profile manufacturing tool assembly that can be used cost- effective in a production line configured to produce integrated matrix composite parts of multi-profile aerospace structures.

There is an object to provide a single-curved or double-curved aerospace door, which is light and cost-effective to produce.

This or at least one of said objects has been achieved by a method of manufacture of a curved aerospace profile article made of fibre reinforced matrix material by means of a profile manufacturing tool assembly, comprising: a first tool device configured to form a curved openbeam profile workpiece; a second tool device configured to divide in longitudinal direction the curved openbeam profile workpiece in at least a first and second profile; a third tool device configured to join the first and second profile to each other for providing said curved aerospace profile article; a fourth tool device configured to cure the curved openbeam profile workpiece or configured to cure the first and second profile prior said joining or after said joining. The method comprises the steps of: providing the first, second, third, and fourth tool device; applying a pre-preg material or a preform material to the first tool device; forming the pre-preg material or preform material into the curved openbeam profile workpiece; dividing the curved openbeam profile workpiece in the first and second profile; joining the first and second profile to each other for providing said curved aerospace profile article; curing the curved openbeam profile workpiece before said dividing step or curing the first and second profile before said joining or curing the first and second profile after said joining; and removing after the curing step the curved aerospace profile article from the fourth tool device.

Alternatively, the step of curing the curved openbeam profile workpiece is performed before said dividing step and/or the step of curing the first and second profile is performed before said joining and/or the step of curing the first and second profile is performed after the joining step.

Alternatively, the step of curing the curved openbeam profile workpiece is followed by a removing step for removing the curved openbeam profile workpiece from the fourth tool device. Alternatively, the step of joining the first and second profile follows the step of dividing the cured curved openbeam profile workpiece of thermoplastic material comprising the reinforcing fibres.

Alternatively, the step of joining the first and second profile is made by welding (e.g. heating) for bondin the first and second profile to each other.

Alternatively, the curved aerospace profile article is removed from the profile manufacturing tool assembly.

In such way is achieved cost-effective and time-saving manufacture of curved aerospace profile articles (e.g. curved J-profiles, C-profiles, l-profiles, L-profiles, T-profiles, T-profiles with opposite flanges, etc.).

Alternatively, the fourth tool device is configured to cure uncured (e.g. a curved openbeam profile workpiece of “dry fibres” embedded in thermoplastic material) and/or semi-cured curved openbeam profile workpiece or configured to cure uncured and/or semi-cured first and second profile prior said joining or after said joining.

Alternatively, the step of forming the pre-preg material or preform material involves application of heat to the pre-preg material or preform material by means of a heating apparatus.

In such way is achieved even more effective and easy forming of a blank of pre-preg and/or preform materials in the first tool device.

Alternatively, the method further comprises the step of curing a plurality of curved openbeam profile workpieces and/or a plurality of first and second profiles joined with a curved panel sheet of fibre reinforced uncured or semi-cured matrix material in a co-curing step.

In such way is achieved a light high strength stiffened curved panel sheet without any profile fasteners (such as bolts and rivets) holding the profiles to the panel sheet.

The manufactured curved panel sheet co-cured with the curved aerospace profile articles lacking panel-profile fasteners, makes it possibly to provide a smooth aerodynamic surface of the curved panel sheet promoting laminar airflow and less fuel consumption of the aircraft.

Alternatively, the cross-section of the first profile corresponds to an L-profile and the cross- section of the second profile corresponds to a Z-profile.

Alternatively, the cross-section of the curved openbeam profile workpiece corresponds to an W-profile or hat-profile. Alternatively, the curved openbeam profile workpiece is formed of a blank of pre-preg or preform material exhibiting a longitudinal central axis, the forming step comprises stretching opposite lateral sides of the blank similarly in a direction from the central axis.

In such way wrinkles are avoided in inner and outer radii of the curved openbeam profile workpiece when formed in the first tool device.

This or at least one of said objects has been achieved by an aerospace panel structure, comprising a single-curved or double-curved panel sheet of fibre reinforced matrix co-cured with a plurality of curved aerospace profile articles.

In such way an aircraft comprising such single-curved or double-curved aerospace door will be lighter and exhibit a smoother aerodynamic surface promoting laminar airflow and less fuel consumption of the aircraft.

Alternatively, the aerospace panel structure is a single-curved or double-curved aerospace door, such as n aircraft cargo door or aircraft passenger door.

This or at least one of said objects has been achieved by a profile manufacturing tool assembly configured for manufacture of a curved aerospace profile article made of fibre reinforced matrix material, the profile manufacturing tool assembly comprises: a first tool device configured to form a curved openbeam profile workpiece; a second tool device configured to divide in longitudinal direction the curved openbeam profile workpiece in at least a first and second profile; a third tool device configured to join the first and second profile to each other for providing said curved aerospace profile article; a fourth tool device configured to cure the curved openbeam profile workpiece or configured to cure the first and second profile prior said joining or after said joining.

Thereby is achieved a manufacture tool assembly that cost-effective manages to manufacture curved aerospace profile articles in series production.

This or at least one of said objects has been achieved by a production line configured for manufacture of curved aerospace profile articles made of fibre reinforced matrix material, the production line comprises the profile manufacturing tool assembly, wherein the production line is configured to manage said method steps.

Alternatively, the production line comprises a control circuitry coupled to the profile manufacturing tool assembly, the control circuit is configured to control the profile manufacturing tool assembly to perform said method steps. In such way is achieved provision to adapt the production line to feature automation in manufacture of curved aerospace profile articles by coupling the control circuitry to a computer programmed for automated manufacturing.

This or at least one of said objects has been achieved by a data medium configured for storing a data program causing in said production line, an automatic or semi-automatic manufacture of an curved aerospace profile article made of fibre reinforced matrix material by means of a profile manufacturing tool assembly, wherein said data program comprises a program code stored on the data medium, which is readable on a computer, for causing the control circuit to perform the method steps of: providing the first, second, third, and fourth tool device; applying a pre-preg material or a preform material to the first tool device; forming the pre-preg material or preform material into the curved openbeam profile workpiece; dividing the curved openbeam profile workpiece in the first and second profile; joining the first and second profile to each other for providing said curved aerospace profile article; curing the curved openbeam profile workpiece before said dividing step or curing the first and second profile before said joining or curing the first and second profile after said joining; and removing said curved aerospace profile article from the fourth tool device.

This or at least one of said objects has been achieved by a data medium product comprising a data medium configured for storing a data program causing in said production line, an automatic or semi-automatic manufacture of an curved aerospace profile article made of fibre reinforced matrix material by means of a profile manufacturing tool assembly, wherein said data program comprises a program code stored on the data medium, which is readable on a computer, for causing the control circuit to perform said method steps, when the data program is run on the computer.

In such way is achieved a manufacture of curved aerospace profile articles in a cost-effective and time saving manner at the same time as human error in forming blanks of pre-pregs and preforms into curved aerospace profile articles being eliminated.

Alternatively, the pre-preg material comprises a layer or layers of reinforcement fibres being pre-impregnated with matrix material.

Alternatively, the matrix material comprises a thermosetting polymer matrix material, thermoplastic material (e.g. polypropylene, polystyrene, cellulose acetate, polyketide, etc.), bio-plastic material or other.

Alternatively, the thermoplastic material may be plastic polymer material becomes flexible or moldable at a certain elevated temperature and solidifies upon cooling. Alternatively, the pre-preg material may be partially cured (in semi-cured state) and exhibiting a viscosity that in “cold state” (e.g. below 25°C) permits easy handling of the lay-up and formed curved openbeam profile workpiece ready to be cut or cured.

Alternatively, the step of forming the pre-preg material into the curved openbeam profile workpiece is followed by a step of cooling the pre-preg material to said “cold state”.

Alternatively, the preform material comprises a plurality of fabric layers (reinforcement fibres) or plies having desired reinforcing properties, which fabric layers or plies or fibres are stabilized to each other by means of a binder resin material configured to maintain the desired shape after application of the preform material in the first tool device.

The curved openbeam profile workpiece formed by the first tool device may comprise reinforcement fibres, wherein the thermoplastic material subsequently is applied into the workpiece of reinforcement fibres and thereafter cured into a curved openbeam profile workpiece comprising the matrix material.

Alternatively, the cured curved openbeam profile workpiece comprising the matrix material is divided in the first and second profile, which are welded to each other forming the curved aerospace profile article by heating the thermoplastic material in at least one portion of the respective first and second profile.

In such way a robot apparatus efficiently manages to remove uncured or semi-cured curved or cured openbeam profile workpiece or first and second profiles from the first tool to the second tool and/or third tool and/or fourth tool.

Alternatively, the first tool device is a hat-profile forming tool operated by at least one robot apparatus.

Alternatively, the second tool device is a cutting tool operated by at least one robot apparatus.

Alternatively, the third tool device is a profile assembly apparatus configured to join the first and second profile to each other and operated by at least one robot apparatus.

Alternatively, the fourth tool device is a curing tool operated by at least one robot apparatus.

Alternatively, the production line may comprise a set of collaborative robots arranged for the assembly of structural aircraft panels, wherein the collaborative robots mount the curved aerospace profile articles to a curved panel for production of structural aircraft panels or mount uncured curved openbeam profile workpieces to an uncured curved panel of fibre reinforced matrix material with subsequently co-curing of the curved panel and curved openbeam profile workpieces into an integral structural aircraft panel.

Alternatively, the reinforcement fibres may comprise carbon fibres, glass fibres, graphite fibres, aramid fibres, micro-fibres and/or micro elements (e.g. nano fibres and/or graphene) or natural fibres and/or others.

Alternatively, the step of applying the pre-preg material on the first tool device is preceded by a step of applying the pre-preg material on a form table for providing a lay-up of pre-preg material constituting a sheet like workpiece of pre-preg material.

Alternatively, the first tool device comprises a male mold tool.

Alternatively, the step of applying the preform material to the first tool device is made by applying the preform material (e.g. dry fibre preform comprising a binder resin material) directly onto the male mold tool or into a female mold tool of the first tool device.

Alternatively, the first tool device comprises the female mold tool having a forming surface into which the blank of fibre reinforced pre-pregs or preform material is applied.

Alternatively, the first tool device configured to form a curved openbeam profile workpiece comprises a first robot apparatus having at least one first end effector and forming tool, configured to apply the lay-up of pre-preg material or preform material onto the first tool device and alternatively configured to form the lay-up of pre-preg material or preform material over the male mold tool or female mold tool.

Alternatively, the first robot apparatus comprises a single arm or dual arm robot configured to form the lay-up of pre-preg material or preform material over the male mold tool.

Alternatively, the at least one first end effector comprises a rolling tool or scraper configured to form the curved openbeam profile workpiece over a forming surface of a male mold tool or female mold tool of the first tool device.

Alternatively, a forming shroud is configured to form the curved openbeam profile workpiece over a male mold tool of the first tool device.

Alternatively, the curved openbeam profile workpiece exhibits, in cross-section transverse to the longitudinal direction of the curved openbeam profile workpiece, a hat-profile, W-profile or other profile suitable for cost-effective forming of the curved openbeam profile workpiece in view of eliminating wrinkles in outer and inner radius of the hat-profile or W-profile. Alternatively, the curved openbeam profile workpiece exhibits a symmetrical geometry in cross-section and comprises opposite first and second flange of a respective opposite first and second web and a head portion joining the first and second web.

Alternatively, the curved openbeam profile workpiece exhibits an unsymmetrical geometry in cross-section and comprises opposite first and second flange of a respective opposite first and second web and a head portion joining the first and second web.

Alternatively, the first tool device is configured to form the curved openbeam profile workpiece by stretching the blank of fibre reinforced pre-pregs or preform material on both sides of the male mold tool or female mold tool of the first tool device in directions transverse from a longitudinal centre line of the curved openbeam profile workpiece or transverse from a longitudinal centre line of the male or female mold tool towards the first and second flanges.

Alternatively, the first tool device exhibits a geometry corresponding with the curved openbeam profile workpiece that promotes stretching of the blank of fibre reinforced pre- pregs or preform material on both sides of the first tool device for avoiding wrinkles in the pre-preg material or preform material.

Alternatively, the rolling tool or scraper tool of the at least one first end effector of the robot apparatus is moved in a first forming step along the head portion of the curved openbeam profile workpiece starting from the middle and outward toward the ends and may securing the pre-preg material or preform material on the first tool device (male or female mold tool).

Alternatively, the rolling tool or scraper tool of at least one second end effector of the robot apparatus is moved in a second forming step along the outer radii between the respective first and second web portion to be formed and the head portion, from the middle outward in longitudinal direction at the same time as the pre-preg material or preform material is bent toward a web forming surface of the first tool device

Alternatively, the rolling tool or scraper tool of the end effectors is moved in a third forming step forming down the first and second webs toward the inner radii (between the respective web portion and flange portion).

Alternatively, a disc tool or similar of the end effectors is moved in a fourth forming step along the inner radii in longitudinal direction forming down the pre-preg material or preform material and forming the first and second flange for avoiding bridging or wrinkling.

Alternatively, a heating element is used during the forming steps for heating the pre-preg material or preform material for optimal forming characteristic. In such way is achieved a curved openbeam profile workpiece that tightly follows a forming surface of the male mold tool of the first tool device avoiding wrinkles and bridging.

However, this type of curved openbeam profile (such as a hat-profile or W-profile or similar) is not regarded as optimally used as a stringer or beam or spar in e.g. an aircraft door or other aircraft structure, as when the flanges are attached to a curved inner surface of a panel sheet it is impossible to reach or visibly inspect the inner sides of the webs.

There is a desire to achieve good reach to the both sides of the web, regarding mounting, maintenance service and inspection.

Alternatively, the forming shroud is configured with a forming surface corresponding with the forming surface of the male mold tool of the first tool device taking into account the curved openbeam profile workpiece formed there between.

Alternatively, the pre-preg material or preform material configured to form the curved openbeam profile workpiece is thicker within a section corresponding with the head portion of the curved openbeam profile workpiece (thicker than the surrounding sections of the pre- preg material or preform material).

In such way is achieved a curved openbeam profile workpiece having high strength and saving weight.

Alternatively, the step of dividing the curved openbeam profile workpiece in the first and second profile is performed manually, semi-automatically or automatically.

Alternatively, the step of dividing the curved openbeam profile workpiece in the first and second profile is performed by means of a second robot apparatus.

Alternatively, the step of dividing the curved openbeam profile workpiece in the first and second profile is made after completely curing of the curved openbeam profile workpiece.

Alternatively, the step of dividing the curved openbeam profile workpiece in the first and second profile is made in semi-cured state of the curved openbeam profile workpiece.

Alternatively, the curved openbeam profile workpiece comprising preform material is subject to a closed mould process comprising matrix application into the mould (e.g. resin transfer molding RTM), wherein the matrix is applied under pressure into the first tool device and through the formed preform material comprising the reinforcing fibres. Alternatively, the curved openbeam profile workpiece made by the closed mould process is divided in the first and second profile after curing of the curved openbeam profile workpiece in the first tool device.

Alternatively, the curved openbeam profile workpiece comprising preform material is divided in the first and second profile prior the closed mould process.

Alternatively, the step of dividing the curved openbeam profile workpiece in the first and second profile is made when the curved openbeam profile workpiece is in contact with the forming surface of the first tool device.

Alternatively, the step of dividing the curved openbeam profile workpiece in the first and second profile is made when the curved openbeam profile workpiece has been removed from the first tool device.

Alternatively, the step of dividing the curved openbeam profile workpiece in the first and second profile is performed by a cutting knife, a rotary cutter knife, a saw, ultrasonic cutting, etc.

Alternatively, the step of dividing the curved openbeam profile workpiece comprises dividing the curved openbeam profile workpiece in a third profile or a strip.

Alternatively, the forming of the curved openbeam profile workpiece comprises applying a stack (lay-up of the sheet like workpiece) of pre-preg material onto the first tool device (e.g. on a top/head surface of the male mold tool).

Alternatively, the stack of pre-preg material is formed down over the male mold tool, wherein the pre-preg material are stretched outward and downward from the top/head surface of the male mold tool (head portion of the curved openbeam profile workpiece being in contact with the top/head surface) for avoiding wrinkles in the inner and outer radius of the curved openbeam profile workpiece.

Alternatively, the first tool device comprises the male mold tool exhibiting the top/head surface (for forming the head portion of the curved openbeam profile workpiece), the respective web forming surface of the male mold tool (for forming the first and second web of the curved openbeam profile workpiece), a respective flange forming surface of the male mold tool (for forming the respective first and second flange each joined to the respective first and second web).

Alternatively, the male mold tool comprises a respective inner radius forming surface (for forming a respective inner radius of the curved openbeam profile workpiece). Alternatively, the male mold tool comprises a respective outer radius forming surface (for forming a respective outer radius of the curved openbeam profile workpiece).

Alternatively, the respective inner radius joins the respective first and second web with the respective first and second flange.

Alternatively, the respective outer radius joins the respective first and second web with the head portion of the curved openbeam profile workpiece.

Alternatively, a cutting tool device configured to divide in longitudinal direction the curved openbeam profile workpiece in at least a first and second profile.

Alternatively, the at least first and second profile each forms an L-profile, configured to be joined “back to back” for forming a T-profile or configured for forming a C-profile or J-profile.

Alternatively, the first profile forms an L-profile and the second profile forms a Z-profile, which are configured to be joined to each other for forming a T-profile having an inner flange.

Alternatively, the curved openbeam profile workpiece exhibits various thickness.

A first step may provide the pre-preg material or the preform material. A second step may apply the pre-preg material or the preform material to the first tool device. A third step may form the pre-preg material or the preform material by means of the first tool device into the curved openbeam profile workpiece.

Alternatively, the forming of the pre-preg material or preform material is performed simultaneously over the male mold tool forming surface at both sides toward the outermost edges (i.e. in opposite directions orthogonally from the longitudinal centre line) of the respective opposite first and second flange.

Alternatively, the third step is followed by curing the pre-preg material.

Alternatively, the third step is followed by injecting matrix material into the preform material followed by curing the curved openbeam profile workpiece comprising the preform material.

Alternatively, the preform is formed in the shape of the desired article.

Alternatively, the preform comprises a plurality of fabric layers or plies that impart the desired reinforcing properties.

Alternatively, the fabric layers or plies may comprise carbon, graphite, aramid or glass fibres. Alternatively, the fabric layers or plies are cut according to a predetermined pattern, loosely bonded or stabilized by means of a binder resin (e.g. matrix or thermoplastic material) so that the fabric layers or plies maintain the desired shape.

Alternatively, the preform is positioned in a closed cavity mold for resin transfer process and matrix resin is injected under pressure to initially wet and impregnate the preform.

Alternatively, the matrix resin initially exhibits low viscosity to enable it to thoroughly impregnate the preform material.

Alternatively, the temperature of the closed cavity mold is set to the cure temperature of the matrix resin causing the matrix resin to increase in viscosity and solidify.

A fourth step may involve dividing the curved openbeam profile workpiece in the first and second profile in cured state or in uncured state or in semi-cured state.

Alternatively, the fourth step is followed by joining cured first and second profile to each other.

Alternatively, the joining of the cured first and second profile to each other is made by adhesive bonding or welding or other suitable method.

Alternatively, the fourth step is followed by joining uncured first and second profile to each other.

Alternatively, the joining of the uncured first and second profile to each other is made by holding the first and second profile to each other and curing the joined first and second profile in one step.

Alternatively, the fourth step is followed by a fifth step for joining semi-cured first and second profile to each other.

Alternatively, the joining of the semi-cured first and second profile to each other is made by holding the first and second profile to each other and curing the joined first and second profile in one step.

Alternatively, the joining of the uncured or semi-cured first and second profile to each other is supplemented by adhesive bonding (e.g. added matrix).

Alternatively, the first and second profile in semi-cured state being joined to each other in accordance with said method and applied onto a single-curved or double-curcved aerospace panel of matrix also being in semi-cured state, wherein the respective first and second profile and single-curved or double-curved aerospace panel being cured together in one single curing step for manufacture of an integrated fibre reinforced matrix aerospace composite part.

Alternatively, the second tool device may comprise a welding tool or adhesive bonding tool configured to bond the first and second profile to each other.

Alternatively, the second tool device may comprise a forming and curing tool configured to join the first and second uncured or semi-cured profile to each other.

Alternatively, the second tool device may comprise a curing tool configured to cure the uncured or semi-cured first and second profile after joining the first and second profile to each other.

Alternatively, a sixth step comprises removing the achieved curved aerospace profile article from the second tool device.

Alternatively, a seventh step comprises deburring of excess material from the achieved curved aerospace profile article by means of a deburring tool for providing a finished curved aerospace profile article.

This or at least one of said objects has been achieved by a curved aerospace article, which curved aerospace article comprises a first profile exhibiting an L-profile in cross-section and a second profile exhibiting a Z-profile in cross-section, wherein the respective first and second profile join each other having in mutual position their respective web portion arranged face to face.

Alternatively, a joint interface is defined between the respective web portion of the first and second profile.

Alternatively, the material properties of the respective web portion being similar.

Alternatively, the joint interface reveals that the curved openbeam profile workpiece has been divided for subsequently joining the respective web portions to each other.

Alternatively, the interface comprises adhesive and/or co-cured plies of pre-preg material and/or welded matrix material.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of examples with references to the accompanying schematic drawings, of which: Fig. 1 illustrates an aircraft having multi-profile aerospace structures comprising curved aerospace profile articles according to the invention;

Figs. 2a-2c illustrate an example of a multi-profile aerospace structure shown in Fig.1 ;

Figs. 3a-3f illustrate a first example of a method of manufacture of a curved aerospace profile article;

Figs. 4a-4h illustrate a second example of a method of manufacture of curved aerospace profile articles also used for the manufacture of multi-profile aerospace structures;

Figs. 5a-5b illustrate a production sequence of providing a curved openbeam profile workpiece to be used according to a third example of manufacture of a curved aerospace profile article;

Figs. 6a-6b illustrate a production sequence of a fourth example of manufacture of a curved aerospace profile article;

Figs. 7a-7c illustrate a production sequence of a fifth example of manufacture of a curved aerospace profile article;

Figs. 8a-8b illustrate a production sequence of a sixth example of manufacture of a curved aerospace profile article;

Figs. 9a-9c illustrate a production sequence of a seventh example of manufacture of a curved aerospace profile article;

Fig. 10 illustrates a production line configured for manufacture of curved aerospace profile article according to an eight example;

Fig. 11 illustrates a production line configured for manufacture of curved aerospace profile article according to a ninth example;

Figs. 12-13 illustrate flowcharts showing exemplary methods of manufacture of a curved aerospace profile article; and

Fig. 14 illustrates a computer configured to control the manufacture of a curved aerospace profile article according to one aspect.

DETAILED DESCRIPTION

Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying schematic drawings, wherein for the sake of clarity and understanding of the invention some details of no importance may be deleted from the drawings.

Fig. 1 illustrates an aircraft 100 having multi-profile aerospace structures 103 comprising curved aerospace profile articles 101. The multi-profile aerospace structures 103 constitutes the aircraft doors 105 positioned in a fuselage 107 of the aircraft 100. The aircraft doors 105 comprise the curved aerospace profile articles 101 serving as structural stiffeners for strengthening the respective aircraft door 105.

Figs. 2a-2c illustrate an example of the multi-profile aerospace structure 103 shown in Fig.1. Fig. 2a shows the multi-profile aerospace structure 103 (aircraft door) comprising curved aerospace profile articles 101 from inside. The multi-profile aerospace structure 103 further comprises a door panel or skin 107. Fig. 2b shows the multi-profile aerospace structure 103 in a side view. The curved aerospace profile articles 101 may be completed by co-curing the door panel or skin 107 with the semi-cured curved aerospace profile articles 101 (workpieces). Alternatively, the curved aerospace profile articles 101 may be fixedly mounted one by one to the door panel or skin 107. Fig. 2c shows the multi-profile aerospace structure 103 in a cross-sectional view A-A taken in Fig. 2b. The profile geometry of the respective curved aerospace profile article 101 may be T-formed with an inner strengthening and mounting flange 109, a so called hook shaped T-profile or J-profile. The inner strengthening and mounting flange 109 may be fixedly mounted to an inner pane 1101 of the multi-profile aerospace structure 103.

The inner strengthening and mounting flange 109 preferably may have an extension in a first plane co-axial with a second plane, in which second plane the bottom flange of the T (the horizontal line in the letter T) extends. The first plane and second plane may also have varying distance from each other dependent on application.

Figs. 3a-3f illustrate a first example of a method of manufacture of a curved aerospace profile article 101 (See Fig. 3f). Fig. 3a shows a first tool 1 having a male forming body 3 having convex flange forming surfaces 5 and a convex head forming surface 7. The male forming body 3 further has parallel web forming surfaces 9, each joining the respective flange forming surface 5. A lay-up of pre-pregs 11 or a fibre preform having reinforcing fibres (not shown) oriented in different directions is applied on the head forming surface 7 by means of a first robot (not shown) or manually. A second robot 13 having a first end effector 15 comprising a rolling tool 17 or scraper is configured to form a curved openbeam profile workpiece (the curved openbeam profile workpiece 19 is shown in Fig. 3d) over the male forming body 3. The rolling tool 17 or scraper is moved in a first forming step along the head forming surface 7 and over the blank of pre-pregs 11 starting from a middle section m and outward toward the ends e and securing the pre-preg material or preform material on the head forming surface 7.

Fig. 3b shows a further example using a shroud 21 of the first tool 1 , which shroud is operated by a robot (not shown) and serves as a female tool 23 having a forming surface 25 corresponding with the forming surfaces 5, 7, 9 (see Fig. 3a) of the male forming body 3 and the formed curved openbeam profile workpiece of pre-pregs 11 there between. The shroud 21 is applied over the blank of pre-pregs 11 and the material of the blank are stretched by means of the shroud 21 and wrinkles are eliminated. This is due to the fact that both sides of the curved openbeam profile workpiece are formed over both sides of the male forming body 3 similarly and the blank will be stretched outwardly during the forming as shown in Fig. 3c.

Such curved openbeam profile workpiece 19 (See Fig. 3d) is thus cost-effective to produce and also suitable for automated production.

However, this type of curved openbeam profile (such as a hat-profile or W-profile or similar) is however not regarded as optimally used as a stringer or beam or spar in e.g. an aircraft door or other aircraft structure, as when its flanges are attached to a curved inner surface of a panel sheet it is impossible to reach or visibly inspect the inner sides of the web portions.

There is a desire to achieve good reach to the both sides of the respective web portion, regarding mounting, maintenance service and inspection.

Nevertheless, such curved openbeam profile workpiece is easy to form by said stretching of the blank during forming (optionally adding heat to the blank) in a simple and straightforward way for avoiding wrinkles in the inner and outer radii. This is achieved simply by stretching the pre-preg material or preform material on both sides of the male forming body 3 (alternatively female forming body) as shown in Fig. 3c.

The pre-preg material (either in uncured state or in cured state or in semi-cured state) or the preform material (either as preform material stabilised by means of a binder material or injected with matrix and cured) of the curved openbeam profile workpiece 19 is divided by a cutting knife 31 as shown in Fig. 3d, thus producing a L-profile workpiece 33 and a Z-profile workpiece 35 as shown in Fig. 3e. The dividing of the curved openbeam profile workpiece 19 may be performed when it remains on the male or female forming body after fulfilled forming or when it has been removed from the male or female forming body. In Fig. 3f is shown that the L-profile workpiece and a Z-profile workpiece have been joined to each other with their web portions arranged face to face for providing the curved aerospace profile article 101.

In case of providing uncured L-profile and Z-profile workpieces of pre-pregs, the assembly of uncured L-profile and Z-profile workpieces of pre-pregs is positioned in a curing tool (not shown), which preferably also maintain the desired form of the “new” profile (of the curved aerospace profile article 101) during curing. After curing, the “new” profile is removed from the curing tool.

In case of providing the L-profile and Z-profile in preform material (as preform material stabilised by means of a binder resin material), the assembly of L-profile and Z-profile workpieces is positioned in a closed mold tool (not shown) configured for resin injection for the application of matrix throughout the fibres of the assembly and subsequently curing.

In case of curing the L-profile and Z-profile workpieces of pre-pregs as separate profiles, the pre-pregs being cured in separate curing tools (not shown) and subsequently the cured L- profile and Z-profile workpieces are joined to each other and bonded to each other by means of an adhesive (not shown).

In case of making separate L-profile and Z-profile of preforms in separate closed mold tools (not shown) configured for resin injection, the cured L-profile and Z-profile workpieces are joined to each other and bonded to each other by means of an adhesive (not shown).

Figs. 4a-4h illustrate a second example of a method of manufacture of curved aerospace profile articles 101 (see Fig. 4g). The method may also be used for the manufacture of a multi-profile aerospace structure 201 (see Fig. 4h).

Fig. 4a shows a forming tool 41 configured to form a curved openbeam profile workpiece 19.

Alternatively, a curing tool (not shown) configured to cure the curved openbeam profile workpiece 19 may be used. A vacuum bag (not shown) is applied over the formed blank of pre-preg material and vacuum is applied via a vacuum line (not shown) for eliminating eventual air pockets from the pre-preg material before/under curing.

After forming of the curved openbeam profile workpiece 19, a robot arm 43 cuts the curved openbeam profile workpiece 19 in elongated profiles of pre-preg material, as shown in Fig. 4b, which elongated profiles are removed (Fig. 4c) after cooling and joined to each other with their web portions 45 face to face, as shown in Fig. 4d. The elongated profiles of pre-preg material is assembled together with radius fillers and an additional inner flange strip 47 for strengthening the curved aerospace profile article, as shown in Fig. 4d.

The assembly of semi-cured profiles and details (radius fillers and strip) of pre-preg material is positioned in a curing tool 49 as shown in Fig. 4e and operation by a robot apparatus 48 and the curing tool 49 also ensuring correct form of the manufactured “new” profile (the curved aerospace profile article 101) during curing as shown in Fig. 4f.

After curing, the curved aerospace profile article 101 (Fig. 4g) is removed from the curing tool 49 and may be mounted to an aircraft door panel 46 for strengthening the aircraft door (the multi-profile aerospace structure 201). As shown in Fig. 4h, the web portion of each curved aerospace profile article 101 is reachable from both sides of the article.

The idea of easy making e.g. a curved hat-profile workpiece having no wrinkles and subsequently dividing the hat-profile workpiece into an L-profile and Z-profile or two L-profiles for joining them into a “new” profile, suitable to be used as e.g. a stringer, the inventors of this disclosure found that this solution well can be subject to automatization in a production line.

Figs. 5a-5b illustrate a production sequence of providing a curved openbeam profile workpiece 19 to be used according to a third example of manufacture of a curved aerospace profile article. Fig. 5a shows a disc tool 54 of an end effector of a robot (not shown) that is moved along the inner radii in longitudinal direction of a male mold tool 56 for forming down pre-preg material or preform material avoiding bridging or wrinkling. Fig. 5b shows an end effector comprising a rolling tool 58 of an end effector of a robot apparatus 59 configured to form the curved openbeam profile workpiece 19 over the male mold tool 56.

Figs. 6a-6b illustrate a production sequence of a fourth example of manufacture of a curved aerospace profile article 101. The curved openbeam profile workpiece 19 in Fig. 6a is cut below an uncurved portion SP of the outer radius as shown in Fig. 6a so that an L-profile L is formed. The L-profile is joined to the remaining Z-profile as shown in Fig. 6b and bonded thereto by means of adhesive and/or co-cured.

Figs. 7a-7c illustrate a production sequence of a fifth example of manufacture of a curved aerospace profile article 101. The curved openbeam profile workpiece 19 is cut below both uncurved portions SP of the outer radii as shown in Fig. 7a so that two L-profiles are formed. The head (top) T is not used in this case, but can be reused. The both L-profiles are joined to each other forming a T-profile (Fig. 7b) or forming a C-profile (Fig 7c). Figs. 8a-8b illustrate a production sequence of a sixth example of manufacture of a curved aerospace profile article 101. The curved openbeam profile workpiece 19 in a plane section adjacent the outer radius as shown in Fig. 8a so that a Z-profile is formed (Fig. 8b) alternatively joined to a complementary structural aerial article (not shown).

Figs. 9a-9c illustrate a production sequence of a seventh example of manufacture of a curved aerospace profile article. A robot arm of a robot apparatus 96 applies a pre-preg or preform material 92 on a male forming tool body 94. The robot apparatus 96 changes tool and uses forming tools 98 operating on both sides (Fig. 9b) of the male forming tool body 94 and stretches the pre-preg or preform material 92 for avoiding any generation of wrinkles.

The robot apparatus 96 changes tool and uses an infrared heating cut element 99 for dividing the curved openbeam profile workpiece 19. The step of forming the pre-preg material or preform material involves application of heat to the pre-preg material or preform material by means of a heating apparatus 95 of the male forming tool body 94.

Fig. 10 illustrates a production line 1001 configured for a method of manufacture of curved aerospace profile articles 101 according to an eight example. The production line 1001 comprises a profile manufacturing tool assembly 1003 comprising a semi-automatic or automatic forming apparatus 1005 configured to form a curved openbeam profile workpiece 19 by forming a lay-up of pre-preg material 1010 over a mold tool 1011 by means of a robot apparatus 1006 of the forming apparatus 1005. The lay-up of pre-preg material 1010 may be laid by means of an automatic tape laying apparatus 1012.

Alternatively, the production line 1001 further may comprises a curing apparatus 1020 for curing the formed pre-preg material.

A cutting tool apparatus 1022 is configured to divide the curved openbeam profile workpiece 19 in longitudinal direction in at least a first 1031 and second 1032 profile by means of a robot apparatus of the cutting tool apparatus 1022. A profile assembly apparatus 1041 of the profile manufacturing tool assembly 1003 is configured to join the first 1031 and second 1032 profile to each other for providing the curved aerospace profile article 101 by means of profile assembly robot 1049. The production line 1001 further may comprise a curing tool 1061 configured to cure the assembled first and second profile 1031, 1032 for providing the curved aerospace profile article 101.

A set of collaborative robots (not shown) may be arranged for the assembly of structural aircraft panels (not shown), such as aircraft door panels, wherein the collaborative robots mount the curved aerospace profile articles to a curved panel (not shown) for production of structural aircraft panels or mount uncured curved openbeam profile workpieces to an uncured curved panel with subsequently co-curing of the curved panel and curved openbeam profile workpieces into an integral structural aircraft panel.

The curved aerospace profile articles 101 are removed from the profile assembly apparatus 1041 by means of an automatic remover 1084 and can be used in further production of aerospace vehicles. The web portion w of each curved aerospace profile article 101 is reachable from both sides of the article when the bottom flange is in contact with a curved panel surface (not shown). The curved aerospace profile articles 101 thus have a web portion w standing alone with open access from the sides and joined to a bottom flange B and to an upper lateral upper flange U, thus forming a so called J-profile.

The production line 1001 comprises the method steps of; firstly providing the automatic tape laying apparatus 1012 or preform layer apparatus, the semi-automatic or automatic forming apparatus 1005 and alternatively the curing apparatus and/or an RTM apparatus, the cutting tool apparatus 1022, the profile assembly apparatus 1041 and alternatively the curing apparatus and/or an RTM apparatus, and the automatic remover 1084. The method comprises the further steps of; applying a pre-preg material or a preform material to the mold tool; forming the pre-preg material or preform material into the curved openbeam profile workpiece; alternatively the forming is made by application of heat to the pre-preg material or preform material by means of a heating apparatus (not shown); alternatively the curing apparatus and/or an RTM apparatus provides a curved openbeam profile workpiece 19; dividing the curved openbeam profile workpiece 19 in a first 1031 and a second 1032 profile; joining the first 1031 and second profile 1032 to each other for providing said curved aerospace profile article 101. That is, curing of the curved openbeam profile workpiece 19 precedes before the dividing step or curing of the first 1031 and second 1032 profile is made before said joining or curing of the first 1031 and second 1032 profile is made after the joining; and removing the curved aerospace profile article 101 from the curing apparatus.

Fig. 11 illustrates a production line 1101 configured for manufacture of curved aerospace profile articles 101 according to a ninth example. The manufacturing will make use of a set of collaborative robots (not shown) arranged together. In a first step A, a first robot apparatus provides the pre-preg material or the preform material to be applied to a forming tool. In a second step B a second robot apparatus applies the pre-preg material or the preform material to the forming tool. In a third step C a third robot apparatus forms the pre-preg material or the preform material in conformity with the forming surface of the forming tool and into a curved openbeam profile workpiece. Alternatively, the forming of the pre-preg material or preform material is performed simultaneously over the forming tool at both sides toward the outermost edges (i.e. in opposite directions orthogonally from the longitudinal centre line or central axis of the forming tool) of the respective opposite first and second flange.

Alternatively, the third step C is followed by curing C1 the formed pre-preg material.

Alternatively, the third step C is followed by injecting matrix material C2 into the preform material and curing the matrix of the curved openbeam profile workpiece.

In a fourth step D a fourth robot apparatus divides the curved openbeam profile workpiece in the first and second profile in cured state or in uncured state or in semi-cured state.

Alternatively, the fourth step D is followed by an assembly step D1 for joining the cured first and second profile to each other.

Alternatively, the fourth step D is followed by a joining step D2 for joining uncured first and second profile to each other.

Alternatively, the joining of the uncured first and second profile to each other is made by holding the first and second profile to each other and curing the joined first and second profile in one single curing step.

Alternatively, in a fifth step E the semi-cured first and second profile are joined to each other by means of a profile assembly apparatus.

Alternatively, the joining of the semi-cured first and second profile to each other is made by holding the first and second profile to each other and curing the joined first and second profile in one single curing step.

A sixth step F comprises removing the produced curved aerospace profile article from the profile assembly apparatus.

A seventh step G may comprise deburring of excess material from the produced curved aerospace profile article by means of a deburring tool for providing a finished curved aerospace profile article. A processor circuitry 900 of the production line described in Fig. 10 and Fig. 11 may comprise a computer 1400 for controlling the manufacture of the curved aerospace profile article made of fibre reinforced matrix material by means of the profile manufacturing tool assembly.

The processor circuitry 900 is coupled to each apparatus configured to operate each step of the manufacture.

Fig. 12 shows a flowchart of an exemplary method of manufacture of a curved aerospace profile article made of fibre reinforced matrix material by means of a profile manufacturing tool assembly. The method starts in a Step 1201. In Step 1202 there is provided a method of manufacture of a curved aerospace profile article by means of a profile manufacturing tool assembly. The profile manufacturing tool assembly comprises a first tool device configured to form a curved openbeam profile workpiece, a second tool device configured to divide in longitudinal direction the curved openbeam profile workpiece in at least a first and second profile, a third tool device configured to join the first and second profile to each other for providing said curved aerospace profile article; and a fourth tool device configured to cure the curved openbeam profile workpiece or configured to cure the first and second profile prior said joining or after said joining. In Step 1203 the method is stopped.

The step 1202 may comprise the steps of providing the first, second, third, and fourth tool device, applying a pre-preg material or a preform material to the first tool device, forming the pre-preg material or preform material into the curved openbeam profile workpiece, dividing the curved openbeam profile workpiece in the first and second profile, joining the first and second profile to each other for providing said curved aerospace profile article, curing the curved openbeam profile workpiece before said dividing step or curing the first and second profile before said joining or curing the first and second profile after said joining, and removing said curved aerospace profile article from the fourth tool device.

Fig. 13 shows a flowchart of an exemplary method of manufacture of a curved aerospace profile article made of fibre reinforced matrix material by means of a profile manufacturing tool assembly. The method starts in a Step 1301. Step 1302 provides the first, second, third, and fourth tool device. Step 1303 comprises applying a pre-preg material or a preform material to the first tool device. Step 1304 comprises forming the pre-preg material or preform material into the curved openbeam profile workpiece. Step 1305 comprises dividing the curved openbeam profile workpiece in the first and second profile. Step 1306 comprises joining the first and second profile to each other for providing said curved aerospace profile article. Step 1307 comprises curing the curved openbeam profile workpiece before said dividing step or curing the first and second profile before said joining or curing the first and second profile after said joining. Step 1308 comprises removing said curved aerospace profile article from the fourth tool device. Alternatively, Step 1309 comprises deburring of excess material from the produced curved aerospace profile article. In Step 1310 the method is stopped.

The flow charts in Fig. 12 and/or 13 may be applied to the production lines described in Fig.

10 and 11.

Fig. 14 illustrates a computer 1400 configured to control the method according to an example. The processor circuitry 900 of the production line described in Fig. 10 and/or Fig.

11 may comprise the computer 1400. The computer 1400 comprises a non-volatile memory NVM 1420, which is a computer memory that can retain stored information even when the computer is not powered. The computer 1400 further comprises a processing unit 1410 and a read/write memory 1450. The NVM 1420 comprises a first memory unit 1430. A computer program (which can be of any type suitable for any operational database) is stored in the first memory unit 1430 for controlling the functionality of the computer 1400.

Furthermore, the computer 1400 comprises a bus controller (not shown), a serial communication port (not shown) providing a physical interface, through which information transfers separately in two directions. The computer 1400 also comprises any suitable type of I/O module (not shown) providing input/output signal transfer, an A/D converter (not shown) for converting continuously varying signals from detectors (not shown) of e.g. a production line and other monitoring units (not shown) into binary code suitable for the computer 1400.

The computer 1400 also comprises an input/output unit (not shown) for adaption to time and date. The computer 1400 also comprises an event counter (not shown) for counting the number of event multiples that occur from independent events in the production line. Furthermore, the computer 1400 includes interrupt units (not shown) associated with the computer for providing a multi-tasking performance and real time computing in e.g. the production line. The NVM 1420 also includes a second memory unit 1440 for external controlled operation.

A data medium storing program P comprising driver routines adapted for apparatus actuators (not shown) and provided for operating the computer 1400 for performing any exemplary method described herein. The data medium storing program P comprises routines for causing (in a production line configured to an automatic or semi-automatic manufacture) a plurality of apparatuses to produce the hollow article. The data medium storing program P comprises a program code stored on a medium, which is readable on the computer 1400, for causing the computer 1400 to perform a method of manufacture of a curved aerospace profile article made of fibre reinforced matrix material by means of a profile manufacturing tool assembly, comprising a first tool device configured to form a curved openbeam profile workpiece; a second tool device configured to divide in longitudinal direction the curved openbeam profile workpiece in at least a first and second profile; a third tool device configured to join the first and second profile to each other for providing said curved aerospace profile article; a fourth tool device configured to cure the curved openbeam profile workpiece or configured to cure the first and second profile prior said joining or after said joining; wherein the method comprises the steps of: providing the first, second, third, and fourth tool device; applying a pre-preg material or a preform material to the first tool device; forming the pre-preg material or preform material into the curved openbeam profile workpiece; dividing the curved openbeam profile workpiece in the first and second profile; joining the first and second profile to each other for providing said curved aerospace profile article; curing the curved openbeam profile workpiece before said dividing step or curing the first and second profile before said joining or curing the first and second profile after said joining; and removing said curved aerospace profile article from the fourth tool device.

The data medium storing program P further may be stored in a separate memory 1460 and/or in a read/write memory 1450. The data medium storing program P is in this embodiment stored in executable or compressed data format.

It is to be understood that when the processing unit 1410 is described to execute a specific function that involves that the processing unit 1410 executes a certain part of the program stored in the separate memory 1460 or a certain part of the program stored in the read/write memory 1450.

The processing unit 1410 is associated with a data port 1499 for communication via a first data bus 1415. The non-volatile memory NVM 1420 is adapted for communication with the processing unit 1410 via a second data bus 1412. The separate memory 1 ^'460 is adapted for communication with the processing unit 1410 via a third data bus 1411. The read/write memory 1450 is adapted to communicate with the processing unit 1410 via a fourth data bus 1414. The data port 1499 may be connectable to data links of the production line 1001 shown in Fig. 10 and/or of the production line 1101 shown in Fig. 11.

When data is received by the data port 1499, the data will be stored temporary in the second memory unit 1440. After that the received data is temporary stored, the processing unit 1410 will be ready to execute the program code, in accordance with the above-mentioned procedure. Preferably, the signals (received by the data port 1499) comprise information about operational status of the production line 1001, 1101, such as operational status regarding e.g. the positions of end effectors of a robot and actual mould body assembly status.

According to one aspect, signals received by the data port 1499 may contain information about actual positions and status of the profile manufacturing tool assembly and respective first, second, third and fourth tool device.

The received signals at the data port 1499 can be used by the computer 1400 for controlling and monitoring a semi-automatic or automatic production line in a cost-effective way. The signals received by the data port 1499 can be used for automatically moving the mould body assembly between the apparatuses and used by the robot per se. The information may be measured by means of suitable sensors arranged at each apparatus of the production line 91. The information may also be manually fed to the processor circuitry 900 via a suitable communication device, such as a personal computer display.

Parts of the method can also be executed by the computer 1400 and the processor circuitry 900, which processor circuitry 900 runs the data medium storing program P being stored in the separate memory 1460 or the read/write memory 1450. When the computer 1400 runs the data medium storing program P, suitable method steps disclosed herein will be executed. A data medium storing program product comprising a program code stored on a medium is provided, which product is readable on a suitable computer, for performing the exemplary method steps herein, when the data medium storing program P is run on the computer 1400.

The present invention is of course not in any way restricted to the preferred examples described above, but many possibilities to modifications, or combinations of the described examples thereof should be apparent to a person with ordinary skill in the art without departing from the basic idea of the invention as defined in the appended claims.

Claims

1. A method of manufacture of a curved aerospace profile article (101) made of fibre reinforced matrix material by means of a profile manufacturing tool assembly (1003), comprising:

-a first tool device (1005) configured to form a curved openbeam profile workpiece (19);

-a second tool device (1022) configured to divide in longitudinal direction the curved openbeam profile workpiece (19) in at least a first and second profile (33, 35);

-a third tool device (1049) configured to join the first and second profile (33, 35) to each other for providing said curved aerospace profile article (101);

-a fourth tool device (1061) configured to cure the curved openbeam profile workpiece (19) or configured to cure the first and second profile (33, 35) prior said joining or after said joining; the method comprises the steps of:

-providing the first (1005), second (1022), third (1049), and fourth (1061) tool device; -applying a pre-preg material or a preform material to the first tool device (1005); -forming the pre-preg material or preform material into the curved openbeam profile workpiece (19);

-dividing the curved openbeam profile workpiece (19) in the first and second profile (33, 35); and

-joining the first and second profile (33, 35) to each other for providing said curved aerospace profile article (101); and -curing the fibre reinforced matrix material.

2. The method according to claim 1, wherein the step of forming the pre-preg material or preform material involves application of heat to the pre-preg material or preform material by means of a heating apparatus (95).

3. The method according to claim 1 or 2, wherein the method further comprises the step of curing a plurality of curved openbeam profile workpieces (19) and/or a plurality of first and second profiles (33, 35) in a co-curing step joined with a curved panel sheet (46) of fibre reinforced uncured or semi-cured matrix material.

4. The method according to any of claims 1-3, wherein the cross-section of the first profile (33) corresponds to an L-profile and the cross-section of the second profile (35) corresponds to a Z-profile.

5. The method according to any of the preceding claims, wherein the cross-section of the curved openbeam profile workpiece (19) corresponds to an W-profile or hat- profile.

6. The method according to any of the preceding claims, wherein the curved openbeam profile workpiece (19) is formed of a blank of pre-preg or preform material exhibiting a longitudinal central axis (x), the forming step comprises stretching opposite lateral sides of the blank similarly in a direction transverse the central axis (X).

7. An aerospace panel structure (107), comprising a single-curved or double-curved panel sheet (46) of fibre reinforced matrix co-cured with a plurality of curved aerospace profile articles (101) manufactured according to claim 3.

8. A curved aerospace article (105), which curved aerospace article (105) comprises a first profile (33) exhibiting an L-profile in cross-section and a second profile (35) exhibiting a Z-profile in cross-section, wherein the respective first and second profile (33, 35) join each other having in mutual position their respective web portion (45) arranged face to face.

9. A profile manufacturing tool assembly (1003) configured for manufacture of a curved aerospace profile article (101) made of fibre reinforced matrix material, the profile manufacturing tool assembly (1003) comprises:

-a fourth tool device (1061) configured to cure the curved openbeam profile workpiece (19) or configured to cure the first and second profile (33, 35) prior said joining or after said joining.

10. A production line (1001, 1101) configured for manufacture of a curved aerospace profile article (101) made of fibre reinforced matrix material, the production line comprises the profile manufacturing tool assembly (1003) according to claim 9, wherein the production line (1001, 1101) is configured to manage the method steps according to any of the claims 1 to 6.

11. The production line (1001, 1101) according to claim 10, wherein the production line (1001, 1101) comprises a control circuit (900) coupled to the profile manufacturing tool assembly, the control circuit (900) is configured to control the profile manufacturing tool assembly (1003) to perform the method steps according to any of claims 1 to 6.

12. A data medium configured for storing a data program (P) causing in a production line (1001, 1101) according to claim 11, an automatic or semi-automatic manufacture of an curved aerospace profile article (101) made of fibre reinforced matrix material by means of a profile manufacturing tool assembly (1003), wherein said data program (P) comprises a program code stored on the data medium, which is readable on a computer, for causing the control circuit (900) to perform the method steps of: -providing the first (1005), second (1022), third (1049), and fourth (1061) tool device; -applying a pre-preg material or a preform material to the first tool device (1005); -forming the pre-preg material or preform material into the curved openbeam profile workpiece (19);

-dividing the curved openbeam profile workpiece (19) in the first and second profile (33, 35);

-joining the first and second profile (33, 35) to each other for providing said curved aerospace profile article (101);

-curing the curved openbeam profile workpiece (19) before said dividing step or curing the first and second profile (33, 35) before said joining or curing the first and second profile (33, 35) after said joining; and

-removing said curved aerospace profile article (101) from the fourth tool device (1061).

13. A data medium product comprising a data medium configured for storing a data program (P) causing in a production line (1001, 1101) according to claim 11, an automatic or semi-automatic manufacture of an curved aerospace profile article made of fibre reinforced matrix material by means of a profile manufacturing tool assembly (1003), wherein said data program (P) comprises a program code stored on the data medium, which is readable on a computer, for causing the control circuit (900) to perform the method steps according to any of claims 1 to 6, when the data program (P) is run on the computer.