KR20010006429A - Apparatus and methods for assembling a helicopter main rotor blade subassembly - Google Patents

Abstract

The present invention relates to an apparatus and method for assembling a helicopter main rotor blade subassembly having a lower airfoil skin, a core, an upper airfoil skin and a spar assembly having a tip and a root, the apparatus comprising: a curved upper airfoil nest ( A lower assembly 202 having a base 206 with a base 206, the curved upper airfoil nest comprising at least two guide lamps disposed proximate the tip and root portions and the curved upper airfoil nest; 214 and 216, wherein at least one of the guide lamps is disposed proximate the root portion and the at least one guide lamp is disposed proximate the tip portion, and a plurality of tip pusher cams 230 are bent upper airfoil nests. Disposed close to. An upper assembly 250 is provided that is configured to mate with the lower assembly and includes a support structure 252 and a flexible impermeable membrane 254 supported by the support structure, wherein the flexible impermeable membrane and bent surface The upper airfoil nest defines a forming cavity therebetween when mating the upper assembly to the lower assembly.

Description

Helicopter blade subassembly assembly apparatus and method {APPARATUS AND METHODS FOR ASSEMBLING A HELICOPTER MAIN ROTOR BLADE SUBASSEMBLY}

In the current aerospace industry, there is an increasing trend in the use of composites for various arrangements, both structurally and dynamically. One particular example of the use of composites is in the manufacture of primary rotor blades for helicopters.

Shikoski Aircraft Co., Ltd. manufactures the blade subassembly and leading-edge sheath simultaneously as separate components, and then combines the prefabricated blade subassembly and the tip sheath together to form a complete main rotor blade. A parallel manufacturing protocol for the manufacture of helicopter main rotor blades has been developed in which the finished main rotor blades are placed in a clamshell and later cured in an autoclave to form the final main rotor blades.

In the process according to the prior art for manufacturing the main rotor blades, the blade subassembly portion of the parallel manufacturing protocol comprises a composite plastic and a honeycomb core combination corresponding to the blade's curved upper airfoil. After positioning inside, position is manually set in span direction and code direction using a plurality of positioning pins. Adhesive-coated titanium spar is manually positioned in a skin and honeycomb core combination combination and seated in a cone in the honeycomb core. The honeycomb core is then coated with an adhesive, and the second composite coating lies on the surface of the honeycomb core and a portion of the spar and is likewise positioned using a positioning pin. A plastic lead, coinciding with the lower curved airfoil of the blade, is placed on the surface of the second composite skin and mated in combination with the plastic nest using a plurality of clamps to provide compactness to the blade subassembly.

The second part of this method for manufacturing the main rotor blade is placing the tip sheath on the exposed tip of the subassembly. The tip sheath has a prefabricated configuration that prevents the sheath from being inserted directly onto the blade subassembly. However, the rear of the tip sheath must be widened to allow the tip sheath to be inserted onto the blade subassembly. Conventional sheath unfolding tools comprise a stainless steel metal sheet grabber having an angle disposed in the span direction in combination with the rear portion of the tip sheath contacting its inner mold line (IML) surface (made of composite material). Each segment of the conventional grabber is actuated individually by the side cam lever, thereby spreading the rear of the tip sheath.

Adhesive is applied to the tip of the blade subassembly, and the blade subassembly tool is then rotated 90 ° to color the appearance of the tip of the blade subassembly. The sheath unfolding tool is then pulled by the crane and lowered onto the blade subassembly tool so that the tip sheath is placed on the tip surface of the blade subassembly. The outer unfolding tool is pulled towards the blade subassembly tool using a plurality of threaded rods until the unfolding tool engages the stop of the predetermined tool.

The process of "drawing" the sheath unfolding tool creates significant stress on the tip sheath. The rear portion of the tip sheath is released by the metal sheet grabber to allow the tip sheath to be fixed on the tip of the blade subassembly.

A major drawback of the blade subassembly tool used in the methods described above is the inadequate density provided to the blade subassembly by a plurality of clamps operated in combination with plastic nests and leads. Specifically, because each clamp provides maximum compaction force only in the spanwise position on the blade subassembly, the compaction force that each clamp merely applies by the tool on the blade subassembly is uneven on the span surface of the blade. .

Through experience with this method and with the blade subassembly tool, the degree of compaction by the clamp ensures that the blade has a dense time in the clamshell and autoclave so that the entire blade assembly does not detach when the finished blade is removed from the blade subassembly tool. It can be seen that about half of it is enough to be placed.

In addition to providing inadequate density on the span surface of the blade subassembly, the conventional blade subassembly tool described above provides inadequate compact coverage in the code direction for the blade subassembly. Since the blade subassembly tool is in a position around the blade subassembly when the external spread tool is actuated, the blade subassembly tool cannot extend sufficiently toward the leading end of the blade subassembly. Thus, a portion of the upper and lower airfoil skins disposed near the tip of the blade subassembly is not dense and therefore cannot be properly secured to the spar. The disadvantage of this incomplete compaction is that when placing the tip sheath on the tip surface of the blade subassembly, if one of the composite skins is separated from the spar, one or both of the rear ends of the tip sheath will slide under the composite skin, leading to the tip sheath. An inadequate interface between the blade and the subassembly will cause the assembled blade to fail.

Another area of interest in the aforementioned parallel manufacturing protocol is the sheath unfolding tool used to integrate the blade subassembly and the tip sheath. Conventional grabbers shear on the IML surface of the tip sheath when the rear end of the tip sheath is widened. Such shearing action by conventional grabbers can cause cracking and peeling of the composite material at the tip, which can cause rejection and rework. In addition, the work of the conventional grabber may contaminate the clean engagement surface of the tip sheath. In addition, the segments of the grabber are operated individually in a continuous manner so that a number of repetitive tasks are required to unfold the entire tip sheath. This process is labor intensive, time consuming and inexpensive, as well as inducing unwanted stresses on the backside of the tip sheath.

Another approach to manufacturing primary rotor blades is disclosed in US Pat. No. 5,528,828, entitled Helicopter Main Rotor Blade Manufacturing Method, and US Patent No. 5,570,631, titled Helicopter Main Rotor Blade Manufacturing Apparatus. . All of these patents have been assigned to United Technologies Corporation. As shown in FIGS. 1 and 2, the apparatus disclosed in U.S. Patent Nos. 5,528,, 828 and 5,570,631 includes a dense fixture 10 for assembling and compacting the blade subassembly 24 and during the compaction process. A blade spreading / inserting device (50) for unfolding and inserting the tip sheath (22) onto the blade subassembly (24), wherein the blade subassembly (24) comprises an upper airfoil skin (12) and a lower airfoil skin (18). ), Core 14 and spar assembly 16.

The dense fixture 10 has a lower assembly 26 corresponding to the curved upper airfoil nest 28, which is mounted in combination with the support structure 30, and a support plate coupled to the structural support truss. And an upper assembly 32 having a pressurized bag 34 which is sealingly fixed in combination with the periphery of 36. The curved top airfoil nest 28 includes a plurality of tool pins 31 for placing the upper airfoil skin 12 thereon and a plurality of back wall pushers for cordwise alignment of the spar assembly 16 thereon. It has a pin 39. A spar strut 40 secured to the support tissue 38 provides a spanwise alignment of the spar assembly 16 within the curved upper airfoil nest 28. Locking the upper and lower assemblies 32, 26 causes the pressure bag 34 to pressurize and densify the assembled blade subassembly components 12, 14, 16, 18.

The exterior spreading / inserting device 50 is combined with the movable struts 52 and the upper and lower elongated carriage members 54 and 56 mounted in synchronous combination with the struts 52 and the carriage members 54 and 56. It has several rows of suction cups 58 and 60 mounted thereon. Pneumatic cylinders 61, 62 are interposed between struts 52 and each individual carriage member 54, 56. The pressurization of the pneumatic cylinders 61 and 62 includes a detachable position in which the tip sheath 22 can be inserted between the upper and lower rows of the suction cups 58 and 60, and the suction cups 58 and 60 are the tip sheath 22. The upper and lower carriage members 54, 56 between the engagement position that abuts the individual outer mold wire (OML) surfaces and the operating position where the tip sheath 22 is unfolded and inserted into the blade subassembly 24 during its compaction. ) Causes synchronization. The vacuum source 64 is pneumatically coupled to the suction cups 58 and 60 to generate suction force in the engaged position such that the suction cups 58 and 60 engage with the individual OML surfaces of the tip sheath 22 to the operating position. Continuous synchronization of the upper and lower carriage members 54 and 56 can straighten the tip sheath 22. The movement of the movable strut 52 places the unfolded tip sheath 22 on the blade subassembly 24 during compaction.

In the above-described blade subassembly tool, the drawback of the apparatus and method disclosed in U.S. Patent No. 5,528,828 and U.S. Patent No. 5,570,631 is that the dense fixture 10 is closely connected to the tip portion 42 of the blade subassembly 24. It does not provide adequate densification between the spar assemblies 16 and portions of the disposed composite skins 12, 18. As shown in FIG. 2, during compaction, the movable strut 52 places the tip sheath 22 on the blade subassembly 24, thereby moving the movable strut 52 to a physically appropriate position. There must be sufficient air gap around the leading end of the blade subassembly 24 so that it can be displaced horizontally. Thus, the pressure bar 34 does not sufficiently cover the tip of the blade subassembly 24, so that the upper and lower airfoil composite skins 12, 18 can be properly compacted on the spar assembly 16 in that area. none. As a result, the tips (also known as "joggles") of these composite skins 12, 18 may have a tendency to pull up the spar assembly 16 in this tip region. These jogs each overlap the corresponding composite skins 12 and 18 so that the tip sheath 22 forms a "stepped" shape to provide a suitable interface between the tip 22 and the blade subassembly 24. In the case of the jog lifting the spar assembly 16, the tip sheath 22 may slide under the influence of the jog during installation, thereby making it unsuitable between the tip sheath 22 and the blade subassembly 24. And forms an unacceptable interface.

In addition, a drawback in the design of the sheath-unfolding / inserting device 50 disclosed in U.S. Patent 5,528,828 and U.S. Patent 5,570,631 is that the interface between the tip sheath 22 and the blade subassembly 24 during installation is inadequate. This may increase the likelihood of occurrence. In particular, when the tip sheath 22 is disposed between the rows of suction cups 58 and 60, the upper and lower carriage members 54 and 56 are in the operating position, and the weight of the tip sheath 22 is determined by the suction cup ( A lower force is generated on the 60 and the lower carriage member 56. Since this lower force on the lower carriage member 56 is not sufficiently canceled by the pressure applied to the lower pneumatic cylinder 62, the lower carriage member 56 moves downward in correspondence with the weight of the tip sheath 22. It is known that there is a tendency. In addition, since the suction cups 58, 60 include rubber bellows, the weight of the tip sheath 22 also collapses the bellows in the lower row of the suction cup 60, and in the upper row of the suction cup 58. The bellows can be inflated. The lower force on the carriage member 56 causes the rear end of the tip sheath 22 to bend downward in relation to the tendency of the lower suction cap 60 to collapse, leading to misalignment of the tip sheath 22 and the blade subassembly 24. Can occur in between. This misalignment is due to the deformation of the tip sheath 22 when the strut 52 moves horizontally and the tip sheath 22 approaches the tip of the blade subassembly 24. It is embedded under the joggles on this lower airfoil composite skin 18 to form an inappropriate interface.

When the strut 52 is closely disposed on the dense fixture 10, the dense fixture 10 and the exterior spreading / inserting device 50 occlude the rear portion of the front portion sheath 22, and the operator makes the rear portion sheath 22. There is a problem that it is difficult to visually observe whether the rear part of the back part is in a proper position for installation. In an effort to correct the uncertainty in rear alignment of the tip sheath 22, the rear end of the tip sheath 22 is extended farther (both sides preferably above 1.27 cm (0.5 in.)) And one of the rear ends jogs. You can't get stuck under either. However, if both sides are expanded beyond 1.27 cm (0.5 in), the composite and heater suitable for the tip sheath 22 may be damaged and reworked due to the stresses generated by excessive spreading.

Summary of the Invention

It is an object of the present invention to provide an apparatus and method for assembling a helicopter main rotor blade subassembly that provides full density in the code and span directions of a blade subassembly.

It is another object of the present invention to provide an apparatus and method for jogging a helicopter main rotor blade that minimizes stress on components of the helicopter main rotor blade subassembly.

It is yet another object of the present invention to provide an apparatus and method for manufacturing a helicopter main rotor blade subassembly that reduces the amount of labor required to raise, move and accurately position the blade subassembly component.

These and other objects include a helicopter main rotor comprising a spar assembly having a tip portion and a root portion comprising a lower assembly constituting a base having a lower airfoil skin, a core, an upper airfoil skin and a bent upper airfoil nest. A blade subassembly assembly device, wherein the curved upper airfoil nest has a root portion and a tip portion, the first and second guide lamps closely disposed in the curved upper airfoil nest, and the first guide lamp is intimately attached to the root portion. And a second guide lamp is arranged intimately at the tip, and a plurality of tip pusher cams are intimately arranged in the bent upper airfoil nest.

An upper assembly is provided that is shaped to mate with the lower assembly, which includes a support structure and a flaky impermeable membrane supported by the flaky impermeable membrane and the bent upper airfoil nest. When mating, a molding cavity is defined between them.

The above object is also achieved by a method of manufacturing a helicopter blade subassembly comprising a lower airfoil skin, a cone formed therein, an upper airfoil skin and a spar assembly having a tip and a root.

The method includes providing a blade compaction device having a lower assembly configured to mate with the upper assembly. The lower assembly includes a base having a curved upper airfoil nest, the base having a root portion and a tip, and at least two guide lamps disposed proximate the curved upper airfoil nest, wherein at least one of the guide lamps is a root. And at least one of the guide lamps is disposed proximate to the tip portion, and the plurality of tip pusher cams are disposed proximate to the curved upper airfoil nest.

The upper assembly includes a support structure for supporting a flexible impermeable membrane, wherein the flexible impermeable membrane and the bent airfoil nest define a forming cavity therebetween when mating the upper and lower assemblies.

The method includes positioning the upper airfoil skin and core in combination with a curved upper airfoil nest, combining the tip support insert with the tip of the spar assembly, and the root of the spar assembly. Engaging the root support insert in combination with the part, wherein the tip support insert and the root support insert each have a guide face and a guide member configured for use in combination with a guide lamp. The spar assembly is arranged in a spanwise direction to the bent upper airfoil nest by abutting at least one of the guide surfaces against at least one of the guide lamps. The spar assembly is positioned in the cord direction in the curved upper airfoil nest by the tip pusher cam by driving the guide member to the cone in the guide lamp and driving the spar assembly to the cone in the core. The lower airfoil skin is then disposed in combination with the core and spar assembly to form a helicopter blade subassembly, and then the upper assembly mates with the lower assembly. The air inside the forming cavity is then depressurized, whereby the flexible impermeable membrane exerts a compacting force on the helicopter blade subassembly.

These objects and other advantages according to the present invention will be readily understood by those skilled in the art from the following detailed description, and preferred embodiments of the present invention are shown and described simply by way of illustration of the best mode for carrying out the present invention. . As can be realized, the invention can be modified in various ways without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive.

The present invention relates generally to manufacturing apparatus and methods, and more particularly, to apparatus and methods for assembling a helicopter main rotor blade subassembly.

1 is a perspective view of a conventional compacting fixture and an exterior spreading / inserting device,

2 is a partial plan view of the conventional device of FIG. 1,

3A is a plan view of the main rotor blade for an H-60 helicopter according to the present invention,

3B is a cross-sectional view of the main rotor blade taken along line 3B-3B in FIG. 3A,

FIG. 3C is a partially enlarged perspective view of the front cover portion shown in FIG. 3B;

3d is a partially enlarged perspective view of the spar assembly for the main rotor blade of FIG. 3a in accordance with the present invention;

4 is a perspective view of a blade compaction apparatus for implementing features in accordance with the present invention;

FIG. 5 is a partial cross-sectional view of the blade compaction device taken along line 5-5 of FIG. 4, including a cross-sectional view of the main rotor blade of FIG. 3B;

FIG. 6 shows a top assembly mating with the bottom assembly, including a cross sectional view of the main rotor blade of FIG. 3B and taken along line 6-6 of FIG.

FIG. 7 is a plan view of a support device for supporting the spar assembly of FIG. 3D and implementing features in accordance with the present invention; FIG.

8 is a partially cut away plan view of the spar assembly and support insert of FIG. 7;

Figure 9 is a plan view of the front end mounting device for implementing the features of the present invention,

FIG. 10 is a schematic diagram showing the interrelationship of the pneumatic cylinder, suction cup, conduit, vacuum pump and vacuum accumulator of the tip exterior mounting device of FIG. 9;

FIG. 11 is a plan view of the front end mounting device of FIG. 9 showing that the front end of the blade subassembly is inserted into the front end.

12 is a flow chart illustrating a method of manufacturing a blade subassembly that implements features in accordance with the present invention.

FIG. 13 is a flow chart illustrating a method of installing a tip sheath on a blade subassembly that implements features in accordance with the present invention. FIG.

Best Mode for Implementing the Invention

The apparatus and method described in detail below include part of a manufacturing protocol for manufacturing a main rotor blade for an H-60 helicopter manufactured by Shikoski Aircraft Corporation. However, it will be appreciated that the devices and methods disclosed herein are generally applicable to main rotor blade manufacture.

Main rotor blade

The H-60 primary rotor blade 100 is shown by way of example in FIGS. 3A-3D, in combination with a leading end 102 and a trailing end 104 that define the cord of the rotor blade 100 in combination. A root portion 106 and a tip portion 108 defining the span of the rotor blades 100 (a tip cap 109 for the main rotor blade 100 is provided for the tip portion 108 of the main rotor blade 100). Manufactured separately for the joints]. The primary rotor blade 100 includes upper and lower airfoil skins 110 and 112, respectively defining the upper and lower aerodynamic surfaces of the blade 100, and a core 114, spar assembly 116 and tip sheath 120. . Upper and lower airfoil skins 110, 112, core 114, and spar assembly 116 define the blade subassembly 132 in combination.

In the illustrated embodiment, the upper and lower airfoil skins 110, 112 are made from several plies of glass fiber woven fabric embedded in a resin permeation processing composite such as a suitable resin matrix of the type known to those skilled in the art. It is prefabricated as a component. The plurality of corresponding rear end tool tabs 130 extends from the rear ends of the upper and lower airfoil skins 110 and 112, and holes 131 are formed in the rear end tool tabs 130, respectively. As will be described in detail below, the rear end tool tabs 130 facilitate proper span and cord positioning of the upper and lower airfoil skins 110 and 112 during the blade assembly process.

In the illustrated embodiment, the core 114 is a honeycomb material of the type commonly used in the aerospace industry, such as NOMEX® (this is Dueye de Neon, Wilmington, Delaware, USA for aramid fibers or fabrics). And a low weight structural reinforcing member between the upper and lower airfoil skins 110 and 112. The leading end of the core 114 defines a cone 121 formed to mate with the trailing end of the spar assembly 116. The upper airfoil skin 110, the lower airfoil skin 112 and the core 114 are arranged in a plurality to facilitate placement of the spar assembly 116 within the blade compaction apparatus 200 as described below. Indicator holes 134 are formed. After the main rotor blade 100 is assembled, the indicator device 134 is unsealed with composite material such that the upper airfoil 110 and the lower airfoil skin 112 have aerodynamic smooth surfaces.

The spar assembly 116 includes a spar 117, one or more counterweights 118, and a back wall block 119. The spar 117 functions as a first reinforcement member of the main rotor blade 100 and acts on torsional, bending, shear and centrifugal mechanical loads that develop within the rotor blade 100 during operation of the helicopter. The spar 117 of the disclosed embodiment is made of titanium, but in a variation, the spar 117 may be made of other materials and may be made of composites or combinations thereof.

The counterweight 118 statically and dynamically balances the main rotor blade 100. In the illustrated embodiment, the counterweight 118 is made from a more dense material, such as foam, tungsten, and lead, respectively, from the less concentrated material in the span direction from the root portion 106 to the tip portion 108, and the main rotor blade 100 may be formed. It provides the weight distribution needed to balance statically and dynamically. Weight 118 is made with a hard point 136 that provides a physical bond between it and the inner mold line (IML) surface of tip sheath 120. The weight 118 is adhesively coupled to the distal end of the spar 117 and is coupled between the distal end portion 120 and the distal end of the spar 117.

The back wall block 119 is adhesively coupled to the rear end of the spar 117 at separate locations corresponding to the indicator holes 134 in the upper airfoil skin 110 and core 114. In the indicator hole 134, the back wall block 119 facilitates the placement of the spar assembly 116 in the blade densification device 200 as described below.

In the illustrated embodiment, the tip sheath 120 shown in more detail in FIG. 3C is a prefabricated hybrid component made of a composite and a corrosion resistant material. The sheath 120 is substantially U-shaped defining the tip 102 of the main rotor blade 100. The sheath 120 comprises one or more plies 122 of a resin permeation process composite such as a glass fiber woven material embedded in a suitable resin matrix, the inner mold line (IML) 120 of the tip sheath 120, the first wear Define strip 124 and second wear strip 126. The tip sheath 120 prevents abrasion of the tip 102 of the main rotor blade 100, controls the airfoil durability of the tip 102 of the main rotor blade 100, and provides an ice shaker assembly of the main rotor blade ( Not shown).

As will be described in more detail below, the method for manufacturing the main rotor blade 100 includes the use of a blade densification device, a support device 300 and a tip exterior installation device 400.

Blade densifier

Referring to FIG. 4, there is provided a blade compaction apparatus 200 having a lower assembly 202 formed to mate with an upper jaw body 250. The lower assembly 202 includes a base 206 having a curved upper airfoil nest 208, the curved upper airfoil nest 208 corresponding to the root portion 106 of the blade subassembly 132. It has an outboard end 212 corresponding to the inboard end 210 and the tip 108 of the blade subassembly 132. Two guide lamps 214, 216 are closely arranged at the inboard end 210 of the curved upper airfoil nest 208, and the guide lamp 216 is outboard of the curved upper airfoil nest 208. It is arranged closely to the bent top airfoil nest 208 so that it is closely arranged at the end 212. Each guide lamp 214, 216 forms a ramp surface 218 therein and terminates at the cone 222. Further, the threaded bolt 224 is disposed in combination with each of the guide lamps 214 and 216 so that the threaded bolt 224 crosses the lamp face 218 by the rotation of the threaded bolt 224. (222).

Three back wall pusher pin recesses 226 are disposed in the curved upper airfoil nest 208 at span and cord directions corresponding to the indicator holes 134 of the blade subassembly 132. As shown in FIG. 5, three back wall pusher pins 228 are formed and used in combination in the indicator hole 226 and the back wall pusher pin recess 226, as fully described below, back wall pushers. The pin 228 may be used for various purposes during the manufacture of the blade subassembly 132. In addition, the three tip pusher cams 230 each have a cam surface 232, and are closely disposed at the tip of the curved upper airfoil nest 208 so that each of the tip pusher cams 230 is a back wall pusher pin recess ( 226 is disposed in the spanwise position corresponding to the 226. The tip pusher cam 230 is constructed in a conventional manner as is known in the art for the cam, such that the cam surface 232 is directed towards the rear wall pusher pin 228 by actuation of the tip pusher cam 230. Proceed in the direction.

4 and 6, the vacuum source 234 has a plurality of conduits 236 disposed in combination with and extending from the base 206, each conduit 236 of the base 206. It ends at the corresponding hole 238. In the illustrated embodiment, the vacuum source 234 comprises a conventional vacuum pump, and the holes 238 are in two rows, one row closely arranged at the tip of the bent upper airfoil nest 208, and It is aligned in a row arranged closely to the rear end of the cotton upper airfoil nest 208. In addition, the five spring loaded tool tab pins 240 are bent upper airfoil nests 208 at the cord and spanwise positions corresponding to the holes 131 of the rear end tool tabs 130 of the blade subassembly 132. It is arranged in a line closely to the rear end of the).

4 and 6, the upper assembly 250 includes a support structure 252 that supports a flexible impermeable membrane 254. In the illustrated embodiment, the support structure 252 is coupled to the base 206 with a plurality of hinges 256 such that the flexible impermeable membrane 254 does not cover the curved top airfoil nest 208. From the position, the flexible impermeable membrane 254 can pivot to a second position that covers the curved upper airfoil nest 208. The support structure 252, the flexible impermeable membrane 254, the curved upper airfoil nest 208 and the base 206 have the support structure 252 in the second position and the flexible impermeable membrane 254 is curved. It is configured to cover the face upper airfoil nest 208, and an airtight seal is formed between the support structure 252 and the base 206. In addition, when the support structure 252 is in the second position, the flexible impermeable membrane 254 and the curved upper airfoil nest 208 form a forming cavity 258 therebetween. In the illustrated embodiment, the apertures 238 of the base 206 may allow the vacuum source 234 to depressurize air from the forming cavity 258 upon operation of the vacuum source 234, thereby providing a flexible impermeable membrane 254. ) Is configured to unfold toward the curved upper airfoil nest 208.

Support device

3A-3D and 7, the support device 300 is provided for use in combination with the blade compaction device 200 during manufacture of the blade subassembly 132. The support device 300 includes a root support insert 302 configured to couple to the root portion 106 of the spar 117 and a tip support insert 304 formed to couple to the tip portion 108 of the spar 117. A crane supporting the tip gearbox 306 coupled to the tip support insert 304, the root gearbox 308 coupled to the root support insert 302 and the root and tip gearboxes 308 and 306. Device 338. In the embodiment disclosed in FIG. 8, the root support insert 302 is a base 310 having a pair of members 312, 314 extending therefrom configured to be inserted into the root 106 of the spar 117. ). One of the members 312 has two spring-loaded prongs 316 extending therefrom for use in combination with the holes 117A of the upper phase corresponding to the spar 117, and the root support insert 302 is sparse. It functions in combination with 117. The tip support insert 304 includes an annular flange 320 inserted into the tip 108 of the spar 117 and is formed with a tip of the spar 117 that secures the tip cap 109 to the blade subassembly 132. It has a plurality of holes 322 corresponding to the holes of 108. Since the plurality of bolts 324 are formed to be used in combination with the holes 322, the tip support insert 304 is disposed and secured to the spar 117.

6 and 8, the support inserts 302, 304 extend in the span direction from the gearbox attachment plate 329 configured to easily attach them to the respective gearboxes 308, 306, respectively, ending there. It further includes two guide members 326 and 328. In the illustrated embodiment, the close guide member 328 at the rear end of the spar assembly 116 is a cylindrical roller configured to engage the ramp surface 218 of the guide ramps 214, 216. Each gearbox attachment plate 329 also has a guide surface 330 disposed on the side of the attachment plate 329 in close proximity to the guide members 326 and 328. As will be described more fully below, the guide members 326 and 328 and the guide surface 330 are configured for use in combination with the guide ramps 214 and 216 to provide a spar assembly during manufacture of the blade subassembly 132. Place 116) as appropriate.

7 and 8, each of the tip gearbox 306 and the root gearbox 308 is configured like a conventional gear device such that each gearbox 306, 308 supports the spar assembly 116. The spar assembly 116 may be rotated about its longitudinal axis 123 and may move in a substantially vertical direction. In this embodiment, the gearboxes 306 and 308 have rotatable cranks 334 and 336 that manually press the spar assembly 116 in the vertical and / or rotational directions. In a variation, an electric motor can be used in combination with the gearboxes 306, 308 to exert vertical and / or rotational motion on the spar assembly 116.

Crane device 338 includes a conventional overhead crane known in the art that can pull material into a manufacturing environment. In the present embodiment, the crane device 338 has a pulling cable 340 connected to each of the gearboxes 306 and 308, the crane device 338 having the gearbox 306 308 in the vertical and / or horizontal direction. ) Can be moved.

Tip exterior mounting device

9, 10, and 11, the front end mounting apparatus 400 includes a lower assembly 402 connected to the lower assembly 450.

The lower assembly 402 includes a base 404 having a plurality of pneumatic cylinders 406 connected thereto and arranged in opposing rows. Each pneumatic cylinder 406 includes a displacement member 408 that can translate in response to the pressurized air provided to the pneumatic cylinder 406 by the pressurized air source 410. The displacement member 408 is coupled to the opposing carriage member 412, which is configured to support the plurality of suction caps 414. The pneumatic cylinder 406, the carriage member 412 and the suction cup 414 can translate synchronously in response to the movement of pressurized air provided by the pressurized air source 410 to the suction cup 414 in opposing rows. .

In the present embodiment, the lower assembly 402 further comprises four vacuum pumps 416 coupled to four vacuum accumulators 418, the vacuum accumulator 418 further comprising a plurality of corresponding conduits ( 422 is used to couple to the plurality of suction cups 414. The vacuum pump 416 and vacuum accumulator 418 function in combination to provide suction to the plurality of suction cups 414. In this embodiment, the plurality of suction cups 414 and corresponding conduits 422 are divided into four conduits, each conduit coupled with one of the vacuum aggregators 418. The plurality of valves 424 are disposed in combination with the conduit 422 and function to adjust the vacuum pressure applied to the plurality of suction cups 414. The vacuum accumulator 418 is a conventional apparatus and provides each suction cup 414 with a vacuum pressure of about 67.73 kPa to about 84.66 kPa (20 in. Hg and 25 in. Hg). The curved front end sheathing nest 420 is interposed between the suction cups 414 in opposite rows and is configured to support the front end sheathing 120. In a variant, the number of vacuum pumps 416, vacuum accumulators 418 and circuits may be different from those of this embodiment to suit the operating conditions of these embodiments.

Upper assembly 450 has five struts 452 positioned spanwise at a position corresponding to the position of rear end tool tab 130 of blade subassembly 132 and extending substantially perpendicularly from base 404. . Each post 452 has a bent surface clamp 454 coupled thereto, and each bent surface clamp 454 has a bent surface 456, a hinged member 458, and a tool tab pin 460. do. The curved surface 456 and the hinged member 458 are configured to clamp the blade subassembly 132 therebetween, and the tool tab pin 460 is combined with the tool tab 130 of the blade subassembly 132. Function to properly position the blade subassembly 132. In this embodiment, each bent surface clamp 454 has an open shape in which the hinge coupling member 458 is located far from the bent surface 456, and the hinge coupling member 458 is in close contact with the curved surface 456. It may have a closed shape that is positioned so as to function to secure the blade subassembly 132. Further, upper assembly 450 extends between bent surface 456 and / or adjacent bent clamp 454 and is disposed in spanwise and cordwise positions corresponding to indicator hole 134 of blade subassembly 132. Three back wall pusher pin recesses 451 are formed in the bridging member (not shown).

The bent surface clamp 454 is coupled to the support 452 to allow the bent surface clamp 454 to translate relative to the bent front end outer nest 420. In this embodiment, the rotating wheel 462 and the differential 464 are formed in a conventional gear and the curved surface for manually forcing the curved surface clamp 454 to translate relative to the curved surface nest 420. Mechanically coupled to clamp 454. In a variant, the translational motion may be provided using an electric motor and / or a hydraulic system.

How to Make a Blade Subassembly

Referring to the flow chart of FIG. 12 and the blade subassembly 132, the blade compaction apparatus 200, and the support apparatus 300 shown in FIGS. 3A to 3D and FIGS. 4 to 8, the blade subassembly ( The manufacturing method MF of 132 will be described.

In step 500, the upper airfoil skin 110 and core 114 are disposed on the upper airfoil nest 208. In this embodiment, the upper airfoil skin 110 and core 114 are adhesively bonded before being stacked on the upper airfoil nest 208 to reduce manufacturing time. In step 502, the combination of the upper airfoil skin 110 and core 114 is disposed by placing the holes 131 in the rear end tool tab 130 with respect to the spring loaded tab pin 240. 208 and span direction and code direction. In addition, the back wall pusher pin 228 is inserted through the indicator hole 134 of the core 114 and the upper airfoil skin 110 and inserted into the back wall pusher pin recess 9226.

In this embodiment, an adhesive (not shown) of a type known in the art that adhesively couples the blade spar to the skin / core combination is applied to the spar assembly 116 before proceeding to step 504. . In step 504, the root support insert 302 is coupled to the root portion 106 of the spar 117 and the tip support insert 304 is coupled to the tip end 108 of the spar 117. . In steps 506 and 508, the root support insert 302 is coupled to the root gearbox 308, and the tip support insert 304 is coupled to the tip gearbox 306 and the gearbox 306, 308. ) Are in turn coupled to the pulling cable 340 so that the spar assembly 116 is supported by the crane device 338.

In step 510, the spar assembly 116 is pulled by the crane device 338 so that the root support insert 302 is guided on the inboard end 210 of the curved upper airfoil nest 208. Closely positioned at 214, the tip support insert 304 is positioned to be closely disposed on the guide ramp 216 on the outboard end 212 of the curved upper airfoil nest 208. In step 512, the guide members 326, 328 of both the root support insert 302 and the tip support insert 304 are engaged with the ramp surface 218 of the guide ramps 214, 216. The spar assembly 116 then spans by contacting the guide surface 330 on the tip support insert 304 against the guide lamp 216 on the outboard end 212 of the bent upper airfoil nest 208. Direction. In step 514, the root gearbox 308 is detached from the root support insert 302 and the tip gearbox 306 is detached from the tip support insert 304.

At step 516, the root portion 106 and tip 108 of the spar assembly 116 are configured such that the guide member 328 proximal to the tip of the spar assembly 116 is a cone of each ramp surface 218. The guide members 326 and 328 are moved to the clamp surface 218 until they engage with the portion 222 so that they are properly positioned in the cord direction. Proper positioning of the root portion 106 and tip portion 108 of the spar assembly 116 need not ensure that the rest of the spar assembly 116 is properly aligned in the cord direction. In order to properly position the entire spar assembly 116 in the cord direction, the tip pusher cam 230 is operated such that the cam surface 232 engages the hard point 136 of the spar assembly 116 and the spar assembly ( The back wall block 119 of 116 is driven with respect to the back wall pusher pin 228. The rear wall pusher pin 228 is arranged in the cord direction so that the rear end of the spar assembly 116 is in the conical portion 121 defined by the core 114 between the rear wall block 119 and the rear wall pusher pin 228. Settle down properly. After the spar assembly 116 is properly positioned, an adhesive (not shown) is applied to the core 114 and the spar assembly 116 to prepare to receive the lower airfoil skin 112.

In step 520, the lower airfoil skin 112 is disposed on the core 114 and the spar assembly 116 and in combination with the spring loaded tool tab pin 240 the lower airfoil skin of the trailing tool tab. 112 is disposed in the span direction and the machine direction. In step 522, the coal plate 242 is disposed on the surface of the blade subassembly 132 (see FIG. 6) and applied to the blade subassembly 132 by the flexible impermeable membrane 254 during compaction. Losing paper functions to distribute density. In step 524, the fiberglass breathable bag 244 is disposed on the surface of the coal plate 242 and decompresses the exhaust of air trapped between the coal plate 242 and the flexible impermeable membrane 254 during compaction. And reduce friction between the blade subassembly 132 and the flexible impermeable membrane 254.

In step 526, the support structure 252 is pivoted in a second position so that the flexible impermeable membrane 254 covers the blade subassembly 132 and the bent upper airfoil nest 208 in place. This forms the hermetic molding cavity 258 between them. In step 528, the vacuum source 234 is operated to evacuate air from the forming cavity 258. In this embodiment, the vacuum pressure supplied by the vacuum source 234 is approximately 44.02 kPa (12 in. Hg). Depressurization of the air from within the forming cavity 258 causes the flexible impermeable membrane 254 to be pulled toward the curved upper airfoil nest 208 to provide compact force to the components of the blade subassembly 132. do. In this embodiment, it is appropriate to provide a compact to the blade subassembly 132 for a compaction period of about 30 minutes at a vacuum pressure of approximately 44.02 kPa (13 in. Hg).

In step 530, the vacuum source 234 is deactivated, the support structure 252 pivots back toward the first position, and the flexible impermeable membrane 254 no longer moves the blade assembly 132. Do not cover. In order to remove the compacted blade subassembly 132 from the blade densifier 200, all of the breathable bag 244, the coal plate 242, the tip pusher cam 230 and the back wall pusher pin 228 are removed. do. In steps 532 and 534, the root support insert 302 is recoupled to the root gearbox 308, the tip support insert 304 is recoupled to the tip gearbox 306, and both gearboxes 306. , 308 is re-attached to the pulling cable 340 so that the blade subassembly 132 is supported by the crane device 338.

In step 536, the threaded bolt 224 is released and the guide members 326, 328 slide away from the ramp surface 218 such that the root support insert 302 and the tip support insert 304 are blade densified. It is no longer limited by the device 200. The blade subassembly 132 is then moved by the support device 300 from the blade compaction device 200 toward the tip exterior installation device 400.

Tip exterior installation method

Referring to the flow chart of FIG. 13 and the blade subassembly 132, the support device 300, and the tip exterior installation device 400 shown in FIGS. 3A to 3D and 7 to 11, the densified blade sub is shown. The method MI for installing the tip sheath 120 in combination with the assembly 132 will be described in more detail.

In order to prepare for the placement of the tip sheath 120 in the tip sheath installation device 400, in step 600, the suction cup 414 of the opposite row is the width w _LES of the tip sheath 120 (see FIG. 3C). In order to check whether there is a suction cup 414 in a detachable position spaced apart by the above distance, the suction cup 414 facing in two rows is checked. In step 602, the tip sheath 120 is disposed within the bent tip sheath nest 420 and is positioned in the span direction when the tool stop (not shown) and the tip of the tip sheath 120 abut. In step 604, the opposing rows of suction cups 414 are provided with a pneumatic cylinder (in a mating position such that each of the plurality of suction cups 414 abuts with the respective outer mold wire (OML) surface of the rear of the tip sheath 120. 406).

In step 606, the vacuum pump 416 operates to accumulate vacuum pressure in each of the corresponding vacuum accumulators 418. In step 608, the valve 424 is opened to open so that the vacuum pressure accumulated in the vacuum accumulator 418 is provided to the plurality of suction cups 414, whereby each of the plurality of suction cups 414 and the front sheath are opened. A suction force is established between the OML surfaces of 120. In this embodiment, each suction cup 414 includes a bellows type device, upon opening of the valve 424, the bellows portion of each suction cup 414 collapses, leading to an OML surface behind the tip sheath 120. The opposite carriage member 412 is drawn. In this embodiment, the suction cup 414 has a bellows portion of each of the suction cups 414 upon application of a vacuum pressure between about 67.73 kPa and about 84.66 kPa (20 in. Hg and 25 in. Hg). The 0.5 in. (Cm) collapses to increase the width (w _LES ) of the tip sheath 120 by about 2.54 cm (1 in.). In the modification, the shape of the suction cup 414 and the magnitude of the suction force applied thereto may be modified from the present embodiment so that the spreading of the tip sheath 120 may be increased or decreased. In addition, the pneumatic cylinder 406 is used to move the suction cups 414 in opposite rows away from each other to achieve additional unfolding of the tip sheath 120.

Prior to placing the blade subassembly 9322 in combination with the tip sheath installation device 400, an adhesive (not shown) is applied to the tip 133 of the blade subassembly 132 so that the tip sheath 120 is attached to the blade subassembly ( 132) can be used to adhesively bond. In step 610, the root and tip gearboxes 306, 308 of the support device 300 are securely almost perpendicular to the tip 133 of the blade subassembly 132 facing the subassembly 132 downward. Adjusted to orient. In step 612, the back wall pusher pin 228 is inserted into the back wall pusher pin recess 451 in the upper assembly 450 of the tip exterior mounting device 400, and the bent surface clamp 454 is placed in an open shape. The hinged member 458 is disposed away from the curved surface 456. In step 614, the blade subassembly 132 is transferred to the bent clamp 454 opened by the support device 300 such that the back wall pusher pins 228 are provided with the upper airfoil skin 110 and the core 114. Is inserted through the indicator hole 134 of and the tool tab pin 460 is inserted through the corresponding tool tap hole 131 so as to properly align the blade subassembly 132 with the tip sheath installation device 400. In step 616, the bent surface clamp 454 is disposed in a closed configuration such that the hinge coupling member 458 is positioned to abut the lower airfoil skin 112 of the blade subassembly 132, thereby allowing the blade subassembly 132 to be positioned. ) Is fixed in the curved surface clamp 454.

In step 618, the root gearbox 308 is detached from the root support insert 302, and the tip gearbox 306 is detached from the tip support insert 304. At step 620, bent surface clamp 454 is moved downwards using rotary wheel 462 such that tip 133 of blade subassembly 132 is inserted into unfolded tip sheath 120. In step 622, the tip 133 and tip sheath 120 of the blade subassembly 132 are visually observed so that the tip 133 of the blade subassembly 132 is properly inserted into the tip sheath 120. The rear portion of the front shell 120 overlaps both the upper and lower airfoil skins 110 and 112. In particular, it is checked in step 622 whether the rear of the tip sheath 120 separates between the spar assembly 116 and one of the upper airfoil skin 110 or the lower airfoil skin 112.

In step 624, the valve 424 in combination with the conduit 422 is closed so that the supply of vacuum pressure to the plurality of suction cups 414 is stopped so that the tip sheath 120 has the blade subassembly 132. To be fitted in combination with the tip 133 of the). In step 626, the bent surface clamp 454 moves upward using the rotating wheel 462 to remove the opposing row of suction cups 414 from the tip 102 of the assembled main rotor blade 100. . In steps 628 and 630, the root support insert 302 is rejoined with the root gearbox 308, and the tip support insert 304 is rejoined with the tip gearbox 306 and then the gearbox 306, 308. ) Are in turn recombined with hoist cable 340 so that main rotor blade 100 is supported by crane device 338.

In steps 632 and 634 the bent surface clamp 454 is opened and the main rotor blade 100 is separated from the tool tap pin 460 and the back wall pusher pin 228 so that the main rotor blade 100 is mounted on the front end. It may be transported by the support device 300 away from the device 400.

It will be readily apparent to those skilled in the art that the present invention fulfills all the purposes set forth above. Through the foregoing specification, those skilled in the art can effectively make various changes and substitutions of equivalents and various other features of the present invention as broadly disclosed herein. Accordingly, the scope of protection of the present invention is not limited only to the definitions obtained in the appended claims and their equivalents.

Claims (12)

A device for assembling a helicopter main rotor blade subassembly comprising a lower airfoil skin, a core, an upper airfoil skin, and a spar assembly, (a) a base having a curved upper airfoil nest having a root and a tip; First and second guide lamps disposed proximate to the curved airfoil, the first guide lamps being disposed proximate the root portion and the second guide lamps disposed proximate the tip portion; A second guide lamp, and A lower assembly having a plurality of tip pusher cams disposed proximate the bent upper airfoil nest; (b) a top assembly configured to mate with a support structure and a flexible impermeable membrane supported by the support structure, (c) the flexible impermeable membrane and the bent upper airfoil nest define a forming cavity therebetween when mating the upper assembly to the lower assembly. The method of claim 1, (a) a tip support insert configured for use in combination with the tip of the spar assembly, (b) a root support insert configured for use in combination with the root portion of the spar assembly, (c) the guide support insert and the root support insert are guide surfaces configured to be used in combination with the guide ramp to position the spar assembly in the cord and span directions, respectively, on the bent upper airfoil nest. And assembly device for a helicopter main rotor blade subassembly having a guide member. The method of claim 2, Each of the guide lamps, (a) a lamp surface defined therein for engaging with the guide member and ending with a cone; (b) a threaded bolt disposed substantially parallel to the ramp surface and capable of translating relative to the cone and operative to press the guide member towards the cone when the guide member engages the lamp surface. Helicopter main rotor blade subassembly assembly device. The method of claim 2, (a) a tip gearbox coupled to the tip support insert, (b) further comprising a root gearbox coupled to the root support insert, (c) the tip and root gearbox are operative to rotate the spar assembly or the helicopter main rotor blade subassembly about the longitudinal axis of the spar assembly, and the spar assembly or the helicopter main rotor blade sub Assembly device for a helicopter main rotor blade subassembly that operates to move the assembly almost vertically. The method of claim 4, wherein And a crane device coupled to the tip and root gearbox, wherein the crane device is a helicopter main rotor blade operative to move the spar assembly or the helicopter main rotor blade subassembly in a substantially vertical and nearly horizontal direction. Assembly device of the subassembly. The method of claim 1, The lower assembly further includes a vacuum source having a plurality of conduits extending therefrom, the bent upper airfoil nest having a plurality of openings, the conduit coupled in fluid communication with the openings, the vacuum source being A device for assembling a helicopter main rotor blade subassembly that operates to depressurize air from a forming cavity. The method of claim 1, The helicopter main rotor blade subassembly further comprises a plurality of rear end tool tabs coupled thereto, each of the rear end tool tabs having a hole formed therein, The lower assembly includes a plurality of spring loaded rear end tool pin pins disposed proximate the bent upper airfoil nest, the spring loaded rear end tab pins being configured to insert into holes in the rear end tool tabs, And said helicopter main rotor blade subassembly is easily positioned on said subassembly in an appropriate span and code direction. A helicopter blade subassembly assembly method comprising a lower airfoil skin, a core having a conical portion therein, and a spar assembly having an upper airfoil skin, a tip portion, and a root portion, comprising: (a) providing a blade densification device having a lower assembly configured to mate with the upper assembly, The lower assembly, A base having a curved upper airfoil nest with a root and a tip; At least two guide lamps disposed proximate the curved upper airfoil nest, defining conical portions therein, at least one disposed proximate the root portion, and at least one disposed proximate the tip portion; A plurality of tip pusher cams disposed proximate the curved upper airfoil nest, The upper assembly includes a support structure for supporting a flexible impermeable membrane, Providing a blade densification device, wherein the flexible impermeable membrane and the curved upper airfoil nest form a forming cavity therebetween when mating the upper assembly to the lower assembly; (b) disposing the upper airfoil skin and core in combination with the bent upper airfoil nest; (c) the tip support insert and the root support insert each have a guide face and a guide member configured for use in combination with the guide lamp, combining the tip support insert in combination with the tip of the spar assembly, Jointly coupling the root support insert with the root portion of the spar assembly; (d) aligning the spar assembly in the span direction at the bent upper airfoil nest by abutting at least one of the guide surfaces and at least one of the guide lamps; (e) arranging the spar assembly in a cordwise direction in the bent upper airfoil by driving the guide member from the guide ramp to the cone and driving the spar assembly from the core to the cone with the tip pusher cam. To do that, (f) disposing the lower airfoil skin in combination with the core and the spar assembly to form a helicopter blade subassembly; (g) mating the upper assembly to the lower assembly; (h) depressurizing and evacuating air from the shaping cavity such that the flexible impermeable membrane exerts a compacting force on the helicopter blade subassembly. The method of claim 8, And installing a coal plate and a breathable bag on the surface of the blade subassembly prior to the step of mating the upper assembly to the lower assembly. The method of claim 8, The lower assembly further includes a vacuum source having a plurality of conduits extending therefrom and terminating in corresponding plurality of openings of the curved upper airfoil nest, the vacuum source being operative to depressurize the air from the forming cavity. How to assemble a helicopter blade subassembly. The method of claim 8, A tip support assembly configured to engage the tip support insert and a root support assembly configured to couple to the root support insert, wherein the tip support assembly and the root support assembly comprise the spar assembly or the blade sub. A method of assembling a helicopter blade subassembly that operates to support an assembly. The method of claim 11, The tip support assembly and the root support assembly, A tip gearbox coupled to the tip support insert and a root gearbox coupled to the root support insert, operable to rotate the spar assembly or blade subassembly about the longitudinal axis of the spar assembly; The tip and root gearbox operative to move the spar assembly or blade subassembly in a substantially vertical direction; A crane device coupled to the tip and root gearbox, wherein the crane device comprises a crane blade subassembly assembly comprising a crane device operable to move the spar assembly or the blade subassembly in a substantially vertical and nearly horizontal direction. Way.