초록 ▼

Methods and systems for manufacturing composite aircraft wings and other structures are disclosed herein. A tool assembly for use in manufacturing composite laminates in accordance with one embodiment of the invention includes a tool plate carried by a movable support system. The tool plate includes

Methods and systems for manufacturing composite aircraft wings and other structures are disclosed herein. A tool assembly for use in manufacturing composite laminates in accordance with one embodiment of the invention includes a tool plate carried by a movable support system. The tool plate includes a tool surface configured to support fiber-reinforced resin material and define an outer mold line (OML) of the fiber-reinforced resin material. The movable support system is configured to respond to signals from a controller to automatically change the shape of the tool surface and alter the OML of the finished part to suit the particular application. In one embodiment, the movable support system can include a plurality of telescoping actuators operably coupled to the tool plate.

대표청구항 ▼

1. A tool assembly for use in manufacturing composite laminates for aircraft, the tool assembly comprising: a tool plate having a tool surface configured to support one or more plies of fiber-reinforced resin material disposed thereon, the tool surface defining an outer mold line of an aircraft lami

1. A tool assembly for use in manufacturing composite laminates for aircraft, the tool assembly comprising: a tool plate having a tool surface configured to support one or more plies of fiber-reinforced resin material disposed thereon, the tool surface defining an outer mold line of an aircraft laminate;a movable support system operably coupled to the tool plate;a composite material applicator;a cutting machine; anda controller operably connected to the movable support system, the composite material applicator, and the cutting machine, wherein the movable support system is configured to respond to signals from the controller to automatically change the shape of the tool surface from a first shape to a second shape, different from the first shape, wherein the composite material applicator is configured to respond to signals from the controller to automatically apply fiber-reinforced resin material to the tool surface after the tool surface has changed into the second shape, and wherein the cutting machine is configured to respond to signals from the controller to automatically form a portion of the fiber-reinforced resin material after the material has been cured. 2. The tool assembly of claim 1 wherein the movable support system includes at least one actuator operably coupled to the tool plate. 3. The tool assembly of claim 1 wherein the movable support system includes at least one actuator operably coupled to the tool plate, and wherein the at least one actuator is at least one of electrically, hydraulically, or pneumatically operable to change the shape of the tool surface. 4. The tool assembly of claim 1 wherein the moveable support system includes a plurality of telescoping actuators operably coupled to the tool plate, and wherein each of the telescoping actuators is extendable and retractable along a central axis to change the shape of the tool surface. 5. The tool assembly of claim 1 wherein the tool surface includes a concave portion configured to support one or more plies of fiber-reinforced resin material for an aircraft wing skin. 6. The tool assembly of claim 1 wherein the tool surface is configured to support one or more plies of fiber-reinforced resin material for an aircraft wing skin, and wherein the moveable support system is configured to respond to signals from the controller to automatically change the shape of the tool surface from a first configuration in which the wing skin has a first camber to a second configuration in which the wing skin has a second camber, different from the first camber. 7. The tool assembly of claim 1, further comprising a base structure that carries the moveable support system, wherein the base structure includes a plurality of rollers for moving the tool plate into and out of a curing station. 8. The tool assembly of claim 1 wherein the tool surface includes a concave portion with a trapezoidal planform configured to support one or more plies of fiber-reinforced resin material for an aircraft wing skin, wherein the moveable support system includes a plurality of telescoping actuators that respond to signals from the controller to automatically change the camber of the tool surface from a first camber to a second camber, different from the first camber, and wherein the tool assembly further comprises a base structure that carries the moveable support system, wherein the base structure includes a plurality of rollers for moving the tool plate into and out of a curing station. 9. The tool assembly of claim 1, further comprising a composite material applicator configured to automatically apply fiber-reinforced resin material to the tool surface in a first pattern corresponding to a first wing and in a second pattern corresponding to a second wing, smaller than the first wing. 10. A tool assembly for use in manufacturing composite laminates for aircraft, the tool assembly comprising: a tool plate having a tool surface configured to support one or more plies of fiber-reinforced resin material disposed thereon, the tool surface defining an outer mold line of an aircraft laminate;a movable support system operably coupled to the tool plate;a controller operably connected to the movable support system, wherein the movable support system is configured to respond to signals from the controller to automatically change the shape of the tool surface from a first shape to a second shape, different from the first shape; anda composite material applicator operably connected to the controller, wherein the composite material applicator is configured to respond to signals from the controller to automatically apply fiber-reinforced resin material to the tool surface in a first pattern corresponding to a first wing and in a second pattern corresponding to a second wing, smaller than the first wing. 11. A tool assembly for use in manufacturing composite laminates comprising: a tool plate having a tool surface configured to support one or more plies of fiber-reinforced resin material disposed thereon, the tool surface defining an outer mold line of a laminate;a movable support system operably coupled to the tool plate;a composite material applicator;a milling machine; anda controller having a processor that transmits signals to the movable support system, the composite material applicator, and the milling machine in accordance with computer-readable instructions stored on memory, wherein the movable support system is configured to respond to signals from the controller to automatically change the shape of the tool surface from a first shape to a second shape, different from the first shape, wherein the composite material applicator is configured to respond to signals from the controller to automatically apply fiber-reinforced resin material to the tool surface after the tool surface has changed into the second shape, and wherein the milling machine is configured to respond to signals from the controller to automatically cut a portion of the fiber-reinforced resin material after the material has been cured. 12. The tool assembly of claim 11 wherein the movable support system includes at least one actuator operably coupled to the tool plate. 13. The tool assembly of claim 11 wherein the movable support system includes at least one actuator operably coupled to the tool plate, and wherein the at least one actuator is at least one of electrically, hydraulically, or pneumatically operable to change the shape of the tool surface. 14. The tool assembly of claim 11 wherein the moveable support system includes a plurality of telescoping actuators operably coupled to the tool plate, and wherein each of the telescoping actuators is extendable and retractable along a central axis to change the shape of the tool surface. 15. The tool assembly of claim 11 wherein the tool surface includes a concave portion configured to support one or more plies of fiber-reinforced resin material for a skin panel. 16. The tool assembly of claim 11 wherein the tool surface is configured to support one or more plies of fiber-reinforced resin material for a skin panel, and wherein the moveable support system is configured to respond to signals from the controller to automatically change the shape of the tool surface from a first configuration in which the skin panel has a first shape to a second configuration in which the skin panel has a second shape, different from the first shape. 17. The tool assembly of claim 11, further comprising a base structure that carries the moveable support system, wherein the base structure includes a plurality of rollers for moving the tool plate into and out of a curing station. 18. The tool assembly of claim 11 wherein the tool surface includes a concave portion configured to support one or more plies of fiber-reinforced resin material for a skin panel, wherein the moveable support system includes a plurality of telescoping actuators that respond to signals from the controller to automatically change the camber of the tool surface from a first camber to a second camber, different from the first camber, and wherein the tool assembly further comprises a base structure that carries the moveable support system, wherein the base structure includes a plurality of rollers for moving the tool plate into and out of a curing station. 19. The tool assembly of claim 11, further comprising a composite material applicator configured to automatically apply fiber-reinforced resin material to the tool surface in a first pattern corresponding to a first laminate and in a second pattern corresponding to a second laminate, smaller than the first laminate. 20. A tool assembly for use in manufacturing composite laminates comprising: a tool plate having a tool surface configured to support one or more plies of fiber-reinforced resin material disposed thereon, the tool surface defining an outer mold line of a laminate;a movable support system operably coupled to the tool plate;a controller operably connected to the movable support system, wherein the movable support system is configured to respond to signals from the controller to automatically change the shape of the tool surface from a first shape to a second shape, different from the first shape; anda composite material applicator operably connected to the controller, wherein the composite material applicator is configured to respond to signals from the controller to automatically apply fiber-reinforced resin material to the tool surface in a first pattern corresponding to a first skin panel and in a second pattern corresponding to a second skin panel, smaller than the first skin panel.