초록 ▼

An aircraft barrel lay-up assembly is provided comprising a barrel mandrel assembly having a contiguous outer barrel lay-up surface. A minor barrel outer surface element is movable between a minor barrel engaged position and a minor barrel disengaged position and forms a minority portion of the con

An aircraft barrel lay-up assembly is provided comprising a barrel mandrel assembly having a contiguous outer barrel lay-up surface. A minor barrel outer surface element is movable between a minor barrel engaged position and a minor barrel disengaged position and forms a minority portion of the contiguous outer barrel lay-up surface when in the engaged position. A major barrel outer surface element is movable between a major barrel engaged position and a major barrel disengaged position. The major barrel outer surface has a first major barrel surface end and a second major barrel surface end moving together to reduce an effective major barrel outer surface circumference when in the major barrel disengaged position. A composite ply assembly is formed around the barrel mandrel circumference and cured while coincident to form a composite barrel element. The composite barrel element removable from said barrel mandrel assembly by way of moving major barrel outer surface element into the major barrel disengaged position such that a sliding gap is formed.

대표청구항 ▼

What is claimed is: 1. An aircraft barrel lay-up assembly comprising: a barrel mandrel assembly defining a contiguous outer barrel lay-up surface forming a barrel mandrel circumference, said barrel mandrel assembly comprising: a minor barrel outer surface element movable between a minor barrel enga

What is claimed is: 1. An aircraft barrel lay-up assembly comprising: a barrel mandrel assembly defining a contiguous outer barrel lay-up surface forming a barrel mandrel circumference, said barrel mandrel assembly comprising: a minor barrel outer surface element movable between a minor barrel engaged position and a minor barrel disengaged position, said minor barrel outer surface forming a minority portion of said contiguous outer barrel lay-up surface when in said minor barrel engaged position, said minor barrel outer surface moving out of continuity with said contiguous outer barrel lay-up surface when in said minor barrel disengaged position; a major barrel outer surface clement movable between a major barrel engaged position and a major barrel disengaged position, said major barrel outer surface element coincident with and forming a majority of said contiguous outer barrel lay-up surface when in said major barrel engaged position, said major barrel outer surface having a first major barrel surface end and a second major barrel surface end moving together to reduce an effective major barrel outer surface circumference when in said major barrel disengaged position, said major barrel outer surface element moving into said major barrel disengaged position in response to said minor barrel outer surface element moving into said minor barrel disengaged position; and a composite ply assembly fanned around said barrel mandrel circumference, said composite ply assembly cured while coincident with said contiguous outer barrel lay-up surface to form a composite barrel element, said composite barrel element removable from said barrel mandrel assembly by way of moving said minor barrel outer surface element into said minor barrel disengaged position and said major barrel outer surface element into said major barrel disengaged position such that a sliding gap is formed between said major barrel outer surface element and said composite ply assembly. 2. An aircraft barrel lay-up assembly as described in claim 1, further comprising: a plurality of major barrel stiffener elements mounted to major barrel inner surface of said major barrel outer surface element; and a first flex zone portion of said major barrel inner surface without said plurality of major barrel stiffener elements; and a second flex zone portion of said major barrel inner surface without said plurality of major barrel stiffener elements, said first flex zone portion and said second flex zone portion allowing said major barrel outer surface element to be flexed between said major barrel engaged position and said major barrel disengaged position. 3. An aircraft barrel lay-up assembly as described in claim 1, further comprising: a minor barrel stiffener element mounted to a minor barrel inner surface of said minor barrel outer surface element. 4. An aircraft barrel lay-up assembly as described in claim 1, wherein said minor barrel outer surface comprises less then twenty percent of said contiguous outer barrel lay up surface. 5. An aircraft barrel lay-up assembly as described in claim 2, wherein said plurality of major barrel stiffener elements comprise: a base stiffener element extending from said first flex zone portion to said second flex zone portion; a first upper stiffener element extending from said first flex zone portion to said first major barrel surface end; a second upper stiffener element extending from said second flex zone portion to said second major barrel surface end. 6. An aircraft barrel lay-up assembly as described in claim 2, wherein said plurality of major barrel stiffener elements comprise a plurality of major barrel truss elements. 7. An aircraft barrel lay-up assembly as described in claim 3, wherein said minor barrel stiffener element comprises a minor barrel truss element. 8. An aircraft barrel lay-tip assembly as described in claim 1, further comprising: a rotatable center support structure in supportive communication with said major barrel outer surface element, said rotatable center support structure including a rotational support mount coincident with a barrel mandrel center point such that said contiguous outer barrel lay-up surface may be rotated about said barrel mandrel center point. 9. An aircraft barrel lay-up assembly as described in claim 8, wherein said rotatable center support structure comprises a rotatable center support barrel including a plurality of air conducting chambers. 10. An aircraft barrel lay-up assembly as described in claim 5, further comprising: a rotatable center support structure mounted to said base stiffener element, said rotatable center support structure including a rotational support mount coincident with a barrel mandrel center point such that said contiguous outer barrel lay-up surface may be rotated about said barrel mandrel center point. 11. An aircraft barrel lay-up assembly as described in claim 1, further comprising: a first major barrel flange positioned at said first major barrel surface end; a second major barrel flange positioned at said second major barrel surface end; a first minor barrel flange positioned on said minor barrel outer surface element, said first minor barrel flange adapted to engage said first major barrel flange when in said minor barrel engaged position; and a second minor barrel flange positioned on said minor barrel outer surface element, said second minor barrel flange adapted to engage said second major barrel flange when in said minor barrel engaged position. 12. An aircraft barrel lay-up assembly as described in claim 11, wherein said first major barrel flange and second major barrel flange comprise inwardly angled flanges. 13. An aircraft barrel lay-up assembly as described in claim 1, wherein said minor barrel outer surface element moves inwardly towards a barrel mandrel center point to move into said minor barrel disengaged position. 14. An aircraft barrel lay-up assembly as described in claim 11, wherein said first minor barrel flange and said second minor barrel flange engage said first major barrel flange and said second major barrel flange as said minor barrel outer surface element moves from said minor barrel disengaged position to said minor barrel engaged position, said minor barrel flanges forcing said major barrel flanges apart such that said effective major barrel outer surface circumference becomes coincident with said barrel mandrel circumference. 15. An aircraft barrel lay-up assembly as described in claim 14, wherein said major barrel outer surface element is biased towards said major barrel disengaged position. 16. An aircraft barrel lay-up assembly as described in claim 2, further comprising: a minor barrel truss element mounted to a minor barrel inner surface of said minor barrel outer surface element. 17. An aircraft barrel lay-up assembly as described in claim 2, wherein said minor barrel outer surface comprises less than twenty percent of said contiguous outer barrel lay up surface. 18. An aircraft barrel lay-up assembly as described in claim 2, wherein said plurality of major barrel stiffener elements comprise: a base truss element extending from said first flex zone portion to said second flex zone portion; a first upper truss element extending from said first flex zone portion to said first major barrel surface end; a second upper truss element extending from said second flex zone portion to said second major barrel surface end. 19. An aircraft barrel lay-up assembly as described in claim 2, further comprising: a rotatable center support structure in supportive communication with said major barrel outer surface element, said rotatable center support structure including a rotational support mount coincident with a barrel mandrel center point such that said contiguous outer barrel lay-up surface may be rotated about said barrel mandrel center point. 20. An aircraft barrel lay-up assembly as described in claim 19, wherein said rotatable center support structure comprises a rotatable center support barrel including a plurality of air conducting chambers. 21. An aircraft barrel lay-up assembly as described in claim 18, further comprising: a rotatable center support structure mounted to said base stiffener element, said rotatable center support structure including a rotational support mount coincident with a barrel mandrel center point such that said contiguous outer point. 22. An aircraft barrel lay-up assembly as described in claim 2, further comprising: a first major barrel flange positioned at said first major barrel surface end; a second major barrel flange positioned at said second major barrel surface end; a first minor barrel flange positioned on said minor barrel outer surface element, said first minor barrel flange adapted to engage said first major barrel flange when in said minor barrel engaged position; and a second minor barrel flange positioned on said minor barrel outer surface element, said second minor barrel flange adapted to engage said second major barrel flange when in said minor barrel engaged position. 23. An aircraft barrel lay-up assembly as described in claim 2, wherein said minor barrel outer surface element moves inwardly towards a barrel mandrel center point to move into said minor barrel disengaged position. 24. An aircraft barrel lay-up assembly as described in claim 22, wherein said first minor barrel flange and said second minor barrel flange engage said first major barrel flange and said second major barrel flange as said minor barrel outer surface element moves from said minor barrel disengaged position to said minor barrel engaged position, said minor barrel flanges forcing said major barrel flanges apart such that said effective major barrel outer surface circumference becomes coincident with said barrel mandrel circumference. 25. An aircraft barrel lay-up assembly as described in claim 24, wherein said major barrel outer surface element is biased towards said major barrel disengaged position. 26. A method of laying up an aircraft barrel assembly comprising: laying up a composite ply assembly around a contiguous outer barrel lay-up surface of a barrel mandrel assembly, said barrel mandrel assembly comprising: a minor barrel outer surface element movable between a minor barrel engaged position and a minor barrel disengaged position, said minor barrel outer surface forming a minority portion of said contiguous outer barrel lay-up surface when in said minor barrel engaged position, said minor barrel outer surface moving out of continuity with said contiguous outer barrel lay-up surface when in said minor barrel disengaged position; a major barrel outer surface element movable between a major barrel engaged position and a major barrel disengaged position, said major barrel outer surface element coincident with and forming a majority of said contiguous outer barrel lay-up surface when in said major barrel engaged position, said major barrel outer surface having a first major barrel surface end and a second major barrel surface end moving together to reduce an effective major barrel outer surface circumference when in said major barrel disengaged position, said major barrel outer surface element moving into said major barrel disengaged position in response to said minor barrel outer surface element moving into said minor barrel disengaged position; curing said composite ply assembly while said minor barrel outer surface element is in said minor barrel engaged position and said major barrel outer surface is in said major barrel engaged position such that a composite barrel element is generated; moving said minor barrel outer surface element into said minor barrel disengaged position; moving said major barrel outer surface element into said major barrel disengaged position such that a sliding gap is formed between said major barrel outer surface element and said composite barrel element; sliding said composite barrel element off of said barrel mandrel assembly. 27. A method as described in claim 26, further comprising: mounting a plurality of major barrel stiffener elements onto a major barrel inner surface of said major barrel outer surface elements; positioning said plurality of major barrel stiffener elements such that a first flex zone portion and a second flex zone portion of said major barrel inner surface are generated; reducing said effective major barrel outer surface circumference by moving said first major barrel surface end and said second major barrel surface end closer together; and moving said first major barrel surface end and said second major barrel surface end closer together by flexing said major barrel outer surface element at said first flex zone portion and said second flex zone portion. 28. A method as described in claim 27, wherein said plurality of major barrel stiffener elements comprise: a base stiffener element extending from said first flex zone portion to said second flex zone portion; a first upper stiffener element extending from said first flex zone portion to said first major barrel surface end; a second upper stiffener element extending from said second flex zone portion to said second major barrel surface end. 29. A method as described in claim 28, further comprising: mounting a rotatable center support structure to said base stiffener element, said rotatable center support structure including a rotational support mount coincident with a barrel mandrel center point; rotating said barrel mandrel assembly about said barrel mandrel center point while laying up said composite ply assembly around said contiguous outer barrel lay-up surface. 30. A method as described in claim 26, further comprising: moving said minor barrel outer surface element inwardly towards a barrel mandrel center point to move into said minor barrel disengaged position. 31. A method as described in claim 26 further comprising: biasing said major barrel outer surface element towards said major barrel disengaged position. 32. A method as described in claim 26 further comprising: biasing said minor barrel outer surface element towards said minor barrel engaged position. 33. A method as described in claim 26, further comprising: moving said minor barrel outer surface element outward away from a barrel mandrel center point to move into said minor barrel engaged position; engaging a first major barrel flange positioned on said first major barrel surface end with a first minor barrel flange positioned on said minor barrel outer surface element as said minor barrel outer surface element moves into said minor barrel engaged position; engaging a second major barrel flange positioned on said second major barrel surface end with a second minor barrel flange positioned on said minor barrel outer surface element as said minor barrel outer surface element moves into said minor barrel engaged position; pushing said first major barrel surface end apart from said second major barrel surface end using said first minor barrel flange and said second minor barrel flange such that said major barrel outer surface moves into said major barrel engaged position. 34. A method as described in claim 26 further comprising: exerting a downward squish force on said composite barrel element to separate said composite barrel element from said major barrel outer surface element. 35. A method as described in claim 34 further comprising: shifting said composite barrel element downwards to generate a continuous removal gap between said barrel mandrel assembly and said composite barrel element; and removing said composite barrel element from said barrel mandrel assembly. 36. A method of laying up an aircraft barrel assembly comprising: laying up a composite ply assembly around a contiguous outer barrel lay-up surface of a barrel mandrel assembly, said barrel mandrel assembly comprising: a minor barrel outer surface element movable between a minor barrel engaged position and a minor barrel disengaged position, said minor barrel outer surface forming a minority portion of said contiguous outer barrel lay-up surface when in said minor barrel engaged position, said minor barrel outer surface moving out of continuity with said contiguous outer barrel lay-up surface when in said minor barrel disengaged position; a major barrel outer surface element movable between a major barrel engaged position and a major barrel disengaged position, said major barrel outer surface element coincident with and forming a majority of said contiguous outer barrel lay-up surface when in said major barrel engaged position, said major barrel outer surface having a first major barrel surface end and a second major barrel surface end moving together to reduce an effective major barrel outer surface circumference when in said major barrel disengaged position, said major barrel outer surface element moving into said major barrel disengaged position in response to said minor barrel outer surface element moving into said minor barrel disengaged position; mounting a plurality of major barrel stiffener elements onto a major barrel inner surface of said major barrel outer surface elements; positioning said plurality of major barrel stiffener elements such that a first flex zone portion and a second flex zone portion of said major barrel inner surface are generated; curing said composite ply assembly while said minor barrel outer surface element is in said minor barrel engaged position and said major barrel outer surface is in said major barrel engaged position such that a composite barrel element is generated; moving said minor barrel outer surface element into said minor barrel disengaged position by way of reducing said effective major barrel outer surface circumference by moving said first major barrel surface end and said second major barrel surface end closer together; moving said first major barrel surface end and said second major barrel surface end closer together by flexing said major barrel outer surface element at said first flex zone portion and said second flex zone portion; moving said major barrel outer surface element into said major barrel disengaged position such that a sliding gap is formed between said major barrel outer surface element and said composite barrel element; sliding said composite barrel element off of said barrel mandrel assembly. 37. A method as described in claim 36, wherein said plurality of major barrel stiffener elements comprise: a base stiffener element extending from said first flex zone portion to said second flex zone portion; a first upper stiffener element extending from said first flex zone portion to said first major barrel surface end; a second upper stiffener element extending from said second flex zone portion to said second major barrel surface end. 38. A method as described in claim 37, further comprising; mounting a rotatable center support structure to said base stiffener element, said rotatable center support structure including a rotational support mount coincident with a barrel mandrel center point; rotating said barrel mandrel assembly about said barrel mandrel center point while laying up said composite ply assembly around said contiguous outer barrel lay-up surface. 39. A method as described in claim 36, further comprising: moving said minor barrel outer surface element inwardly towards a barrel mandrel center point to move into said minor barrel disengaged position. 40. A method as described in claim 36 further comprising: biasing said major barrel outer surface element towards said major barrel disengaged position. 41. A method as described in claim 36, further comprising: moving said minor barrel outer surface element outward away from a barrel mandrel center point to move into said minor barrel engaged position; engaging a first major barrel flange positioned on said first major barrel surface end with a first minor barrel flange positioned on said minor barrel outer surface element as said minor barrel outer surface element moves into said minor barrel engaged position; engaging a second major barrel flange positioned on said second major barrel surface end with a second minor barrel flange positioned on said minor barrel outer surface element as said minor barrel outer surface element moves into said minor barrel engaged position; pushing said first major barrel surface end apart from said second major barrel surface end using said first minor barrel flange and said second minor barrel flange such that said major barrel outer surface moves into said major barrel engaged position. 42. A method as described in claim 26 further comprising: exerting a downward squish force on said composite barrel element to separate said composite barrel element from said major barrel outer surface element; shifting said composite barrel element downwards to generate a continuous removal gap between said barrel mandrel assembly and said composite barrel clement; and removing said composite barrel element from said barrel mandrel assembly.