Multiple head automated composite laminating machine for the fabrication of large barrel section components

Abstract

An aircraft part manufacturing device for automated composite lamination on a mandrel surface of a tool having a rotational axis includes a mechanical supporting structure that supports multiple material delivery heads. The tool is moveable and rotatable relative to the mechanical supporting structure. The mechanical supporting structure provides for axial translation of the material delivery heads relative to the mandrel surface while the mandrel surface is rotated for laying down courses of composite material over the entire mandrel surface of the tool. The position and movement of each of the plurality of material delivery heads is individually adjustable. Arm mechanisms provide motion of each material delivery head in a direction normal to the mandrel surface; rotation about an axis normal to the mandrel surface; circumferential position adjustment in a hoop direction relative to the mandrel surface; and axial position adjustment relative to the other material delivery heads.

1 . A system, comprising:
 a structure;   a mandrel comprising a mandrel surface which substantially conforms to a section of a vehicle, wherein the mandrel is rotatable relative to said structure and wherein the structure is moveable relative to the mandrel; and   a plurality of material delivery heads supported by said structure, wherein each of said plurality of material delivery heads is designed to move relative to the mandrel surface during fabrication of the section of the vehicle and apply material along the mandrel surface while individually adjusting positions relative to the mandrel surface and the other material delivery heads during application of the material.   
   
   
       2 . The system of  claim 1 , wherein the material is a composite material, and wherein the system is for fabricating a section of an aircraft fuselage via automated composite lamination on the mandrel surface. 
   
   
       3 . The system of  claim 2 , wherein each of the material delivery heads is designed to apply the composite material in a fiber orientation that is independent of fiber orientations of the other material delivery heads. 
   
   
       4 . The system of  claim 2 , wherein the structure is a mechanical supporting structure which provides for movement of said plurality of material delivery heads relative to the mandrel surface during fabrication of the section of the vehicle. 
   
   
       5 . The system of  claim 1 , wherein the material is a composite material and wherein the vehicle comprises an aircraft fuselage, and wherein each of said plurality of material delivery heads is: designed to apply composite material along the mandrel surface during fabrication of the section of the aircraft fuselage; and individually positionally adjustable relative to the mandrel surface and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage. 
   
   
       6 . The system of  claim 1 , wherein the mandrel further comprises a rotational axis, and wherein each of said plurality of material delivery heads is rotatable about another axis substantially normal to the axis during application of the material by the material delivery heads. 
   
   
       7 . The system of  claim 6 , wherein at least one of the material delivery heads is designed to apply composite material at a first angle relative to the mandrel, while at least one of the other material delivery heads is simultaneously applying composite material at a second angle, different than the first angle, relative to the mandrel. 
   
   
       8 . In a system comprising a structure, a plurality of material delivery heads supported by said structure, and a mandrel comprising a mandrel surface which substantially conforms to a section of a vehicle, a method for fabricating the section of the vehicle, comprising:
 rotating the mandrel relative to said structure while moving the structure relative to the mandrel;   moving said plurality of material delivery heads relative to the mandrel surface to apply material along the mandrel surface during fabrication of the section of the vehicle, and individually adjusting positions of at least some of the material delivery heads relative to the mandrel surface and relative to at least one of the other material delivery heads during application of the material.   
   
   
       9 . The system of  claim 1 , wherein the material is a composite material, and wherein the vehicle is a section of an aircraft fuselage fabricated by automated composite lamination on the mandrel surface. 
   
   
       10 . The system of  claim 9 , wherein each of the material delivery heads is designed to apply the composite material in a fiber orientation that is independent of fiber orientations of the other material delivery heads. 
   
   
       11 . The system of  claim 9 , wherein the structure is a mechanical supporting structure, and wherein the mechanical supporting structure provides for movement of said plurality of material delivery heads relative to the mandrel surface during fabrication of the section of the vehicle. 
   
   
       12 . The system of  claim 8 , wherein the material is a composite material, wherein the vehicle comprises an aircraft fuselage, and wherein each of said plurality of material delivery heads is: designed to apply composite material along the mandrel surface during fabrication of the section of the aircraft fuselage; and individually positionally adjustable relative to the mandrel surface and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage. 
   
   
       13 . The system of  claim 8 , wherein the mandrel further comprises an axis, and wherein each of said plurality of material delivery heads is rotatable about another axis substantially normal to the axis during application of the material by the material delivery heads. 
   
   
       14 . The system of  claim 13 , wherein at least one of the material delivery heads is designed to apply composite material at a first angle relative to the mandrel, while at least one of the other material delivery heads is simultaneously applying composite material at a second angle, different than the first angle, relative to the mandrel. 
   
   
       15 . A system for fabricating a section of a vehicle, the system comprising:
 a mandrel having a mandrel surface which substantially conforms to the section of the vehicle; and   a plurality of material delivery heads, wherein at least two of the material delivery heads are designed to apply composite material along the mandrel surface of the mandrel during fabrication of the section of the vehicle and to individually adjust positions relative to the mandrel surface and with respect to one or more of the other of the material delivery heads during application of the composite material by the at least two of the material delivery heads.   
   
   
       16 . The system of  claim 15 , wherein the mandrel is rotatable relative to said plurality of material delivery heads, and further comprises:
 an axis, wherein the at least two of the material delivery heads are designed to move relative to the mandrel surface during application of the composite material by the material delivery heads.   
   
   
       17 . A method for fabricating a section of a vehicle, the method comprising steps of:
 applying a composite material to a mandrel surface from at least two material delivery heads, while moving at least some of said material delivery heads relative to the mandrel surface during application of the composite material; and   individually adjusting positions of the at least some two material delivery heads relative to the mandrel surface and the other material delivery heads during application of the composite material along the mandrel surface by the material delivery heads during the fabrication of the section of the vehicle.